Gearbox 02R PDF

Service 5
Workshop Manual
FABIA 2000 ³
Gearbox 02R
Edition 07.00
Gearbox code EMD EWT GGU GGV
Service Department. Technical Information Printed in Czech Republic

S00.5317.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5317.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ Gearbox 02R
List of Supplements to Workshop Manual

FABIA 2000 ³
Gearbox 02R
Edition 07.00
Supple-
Edition Subject Article Number
ment
07.00 Basic Edition S00.5317.00.20
1 11.00 Supplement to Basic Edition S00.5317.01.20
2 02.03 Supplement to manual gearbox with code GGU S00.5317.02.20
3 08.03 Supplement to manual gearbox with code GGV S00.5317.03.20
Edition 08.03 List of Supplements

S00.5317.03.20
List of Supplements Edition 08.03

S00.5317.03.20
Table of Contents
00 – Technical Data
Identification of the gearbox ......................................................................... 00-1 page 1
- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1 page 2
Overview of Power Transmission .................................................................. 00-2 page 1
- Designation of components and transmission ratio .............................................. 00-2 page 1
General Repair Information .......................................................................... 00-3 page 1
30 – Clutch
Clutch control ........................................................................................... 30-1 page 1
- Summary of components - Foot controls .......................................................... 30-1 page 1
- Removing and installing the over-centre helper spring .......................................... 30-1 page 3
- Removing and installing the clutch pedal .......................................................... 30-1 page 4
- Summary of components - Hydraulics ............................................................. 30-1 page 5
- Removing and installing the master cylinder ...................................................... 30-1 page 6
- Removing and installing the slave cylinder ........................................................ 30-1 page 8
- Bleeding the clutch system .......................................................................... 30-1 page 9
Repair of the clutch control .......................................................................... 30-2 page 1
Repairing the clutch ................................................................................... 30-3 page 1
34 – Control/Housing
Shift mechanism ........................................................................................ 34-1 page 1
- Fitting location of shift mechanism .................................................................. 34-1 page 1
I - Summary of components - gearshift knob and cover ...................................... 34-2 page 1
- Separating collar from gearshift lever .............................................................. 34-2 page 2
II - Summary of components shift lever and shift housing ................................... 34-3 page 1
III - Summary of components - Control cables ................................................. 34-4 page 1
Removing and Installing Shift Mechanism ...................................................... 34-5 page 1
- Removing ............................................................................................... 34-5 page 1
- Installing ................................................................................................ 34-5 page 2
Setting shift mechanism .............................................................................. 34-6 page 1
- Operation ............................................................................................... 34-6 page 3
Removing and installing the gearbox ............................................................. 34-7 page 1
- Removing ............................................................................................... 34-7 page 1
- Installing ................................................................................................ 34-7 page 7
Inspecting gear oil ..................................................................................... 34-8 page 1
Disassembling and assembling the gearbox .................................................... 34-9 page 1
- I - Disassembling and assembling gearbox housing cover and 5th gear .................... 34-9 page 2
- II - Disassembling and assembling gearbox housing and gearshift mechanism ............ 34-9 page 3
- III - Disassembling and assembling the drive shaft, output shaft, differential and gearshift
forks ..................................................................................................... 34-9 page 4
- Mounting sequence ................................................................................... 34-9 page 4
Repairing the gearbox housing and the clutch housing ...................................... 34-10 page 1
Disassembling and assembling the gearshift mechanism on the gearbox side ........ 34-11 page 1
Disassembling and assembling the gearshift forks ............................................ 34-12 page 1
Edition 08.03 Table of Contents I

S00.5317.03.20
35 – Wheels, shafts
Disassembling and assembling the drive shaft ................................................. 35-1 page 1
Setting drive shaft ..................................................................................... 35-2 page 1
- Adjusting washer table ............................................................................... 35-2 page 2
- Perform control measurement ....................................................................... 35-2 page 3
Disassembling and assembling the output shaft ............................................... 35-3 page 1
Setting output shaft ................................................................................... 35-4 page 1
- Determine the adjusting screw ...................................................................... 35-4 page 1
Disassembling and assembling the reverse shaft ............................................. 35-5 page 1
39 – Final drive/Differential
Replacing the flange shaft gasket rings (gearbox fitted) .................................... 39-1 page 1
- Replacing flange shaft gasket rings ................................................................ 39-1 page 1
Disassembling and assembling the differential ................................................. 39-2 page 1
Setting overview ........................................................................................ 39-3 page 1
Adjusting the differential gear ...................................................................... 39-4 page 1
Table of Contents Edition 08.03

II S00.5317.03.20
FABIA 2000 ³ Gearbox 02R 00
00 – Technical Data
00-1 Identification of the gear-

box
Assignment ⇒ 00-1 page 2
Location on the gearbox
2
1
Identification characters and manufacturing date -arrow
1-.
Identification of gearbox 02R -arrow 2-.
V34 - 1964
Identification characters and manufacturing date of

the gearbox
Exam- EMD 12 04 0
ple:
I I I I
Identifi- Day Month Manufac-
cation turing
charac- year
ters (2000)
S34-0521
Identification of gearbox 02R -arrow 2-.
2
S34-0515
Edition 08.03 Identification of the gearbox 00-1 page 1

S00.5317.03.20
00 FABIA 2000 ³ Gearbox 02R
Identification characters, aggregate assignment, ratios, capacities
Manual gearbox 5 speed 02R

Identification characters EMD EWT1) GGU GGV
Manu- from 03.00 09.00 11.02 08.03
factured through 08.00 10.02
Assign- Engine 1.9 ltr./74kW 1.4 ltr./55 kW TDI
ment:
Ratio: Final drive 60:19 = 3.158 61:18 = 3.389
Z2 : Z 1 1. Gear 34:09 = 3.778 33:10 = 3.300
2. Gear 33:16 = 2.063 35:18 = 1.944
3. Gear 30:23 = 1.304 34:26 = 1.308
4. Gear 28:31 = 0.903 34:35 = 0.971
5. Gear 28:40 = 0.700 34:45 = 0.756
Reverse gear 18:09 x 36:20 = 3.600 17:10 x 36:20 = 3.060
Speedometer2) 13:22 = 0.591
Capacity 2.0 litre
Specification Gearbox oil G 005 000 SAE 75W90 (synthetic oil)
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch plate ∅ 228 mm3)
Drive shaft flange ∅ 100 mm
1) Gearbox with modified synchronisation
2) Only on vehicles without ABS.
3) This serves as information. Assign the clutch disc and the pressure plate following the spare parts catalogue.
Identification of the gearbox Edition 08.03

00-1 page 2 S00.5317.03.20
00-2 Overview of Power Transmission

Designation of components and transmission ratio
Note
The arrows point in the direction of travel.
1- Engine
2- Clutch
3- Gearbox
4- Drive shaft
5- Output shaft/input shaft
6- Differential
I- 1. Gear
3 4 2 1
II - 2. Gear
III - 3. Gear V IV IIIIIR I
IV - 4. Gear
V- 5. Gear
R- Reverse gear
A- Final drive
T- Speedometer drive
5 A 6 T
N35-0020
Edition 07.00 Overview of Power Transmission 00-2 page 1

S00.5317.00.20
Overview of Power Transmission Edition 07.00

00-2 page 2 S00.5317.00.20
00-3 General Repair Informa-

tion
Scrupulous care and cleanliness as well as the proper
tools are essential requirements for carrying out proper
and successful gearbox repairs. Obviously, the generally
valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair op-
erations - which are otherwise listed several times at nu-
merous points in the workshop manual - are summarized
here. They apply to this workshop manual.
Gearbox
♦ When installing, ensure the dowel sleeves are correct-
ly located between the engine and gearbox.
♦ If the gearbox is replaced, pour in gear oil up to lower
edge of filler hole.
♦ Capacity and specification ⇒ Chap. 00-1
Gaskets, seals
♦ Thoroughly clean contact surfaces and apply sealant
AMV 188 200 03.
♦ Apply sealant evenly - not too thick.
♦ Replace O-rings.
♦ Replace radial shaft seals.
Before installing:
Lightly oil the outer diameter and pack half the space be-
tween the sealing lips -arrow- with sealing grease
-G 052 128 A1-.
After installing:
Check gear oil level, if necessary pour in up to lower edge
of filler hole, specification ⇒ Chap. 00-1.
Locking elements
♦ Replace circlips.
♦ Do not over-tension circlips.
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: slot longitudinally to
power flow -arrow-.
Bolts, nuts
♦ Slacken and tighten nuts and bolts for attaching cov-
ers and housings diagonally across.
♦ Do not twist particularly sensitive parts - e.g. clutch
pressure plates - and slacken and tighten diagonally
across in stages.
♦ Tightening torques apply for non-oiled nuts and bolts.
♦ Always replace the self-locking nuts and bolts.
♦ It is important to ensure at all bolted connections that
the contact surfaces as well as the nuts and bolts are
waxed only after being installed, should this be neces-
sary.
Bearings
Edition 07.00 General Repair Information 00-3 page 1

S00.5317.00.20
♦ Install new taper roller bearings as supplied, and do

not oil additionally.
♦ Insert needle bearings in gearbox with gear oil.
♦ Always replace all the taper roller bearings fitted to a
shaft. Use the same make of bearings, if possible!
♦ Heat inner races to about 100 °C for installing.
♦ Do not mix up the outer and inner races of bearings of
the same size as the bearings are matched.
♦ Position needle bearing with the inscribed side (thick-
er metal wall) facing the insertion drift.
Shims
♦ Gauge shims at several points with a micrometer. Dif-
ferent tolerances allow to measure the required thick-
ness for each washer very precisely.
♦ Inspect for burrs and damage.
♦ Install only shims which are in perfect condition.
Synchronizer rings
♦ Do not interchange. Assign synchronizer rings to the
same gear when re-using.
♦ Inspect for wear, replace if necessary.
♦ Insert with gearbox oil.
Gears
♦ Clean and heat on a heating plate to about 100°C be-
fore pressing on.
♦ The temperature can be verified with a temperature
measuring device (e.g. -V.A.G 1558-).
General Repair Information Edition 07.00

00-3 page 2 S00.5317.00.20
30 – Clutch
30-1 Clutch control
Summary of components - Foot controls

Special tools, test and measuring equipment and
auxiliary items required
♦ Pliers -T10005-
♦ Polycarbamide grease -G 052 142 A2-
Note
♦ Summary of components - Hydraulics ⇒ 30-1
page 5.
♦ Disconnect earth strap from battery.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
♦ If the battery earth strap is disconnected and connect-
ed, carry out additional operations ⇒ Electrical Sys-
tem; Rep. Gr. 27.
♦ Grease all bearing and contact surfaces with polycar-
bamide grease -G 052 142 A2-.
♦ Prior to working on the foot controls remove the stor-
age area on the driver's side ⇒ Body Work;
Rep. Gr. 70.
Edition 02.03 Clutch control 30-1 page 1

S00.5317.02.20
1 - Support/Front wall
T for master cylinder and
bracket
1
2 - Gasket
2
T always replace 3
3 - Bracket
4 - Screw
4 5
5 - Gas/brake foot controls
6 - 28 Nm 6
T always replace
7 - Clutch pedal switch
T Push the clutch pedal down
when removing or installing 19 20
the switch.
T before removing the clutch
7
pedal ⇒ item 11 remove the
18
switch by rotating it 90° to the 8
right and drawing it through 9
the assembly opening. 17
T when installing guide switch
through the assembly open- 16 10
ing and turn to the left up to 9
the stop 11
8 - Over-centre helper spring
T removing and installing
⇒ 30-1 page 3
9 - Spacer bush 15
10 - Bushing 14
11 - Clutch pedal 13
T removing and installing 12
⇒ 30-1 page 4 S30-0066
12 - Support
T removing and installing ⇒ 30-1 page 6
13 - 28 Nm
T always replace
14 - Master cylinder
15 - Retaining clip
T to remove and install the tube-hose line pull out retaining clip up to the stop.
16 - Tubing
17 - Bearing
T insert in bracket
T always replace
T Fitting position: the peg -arrow- locks into the master cylinder recess
18 - Screw
T Pedal stop on bracket
19 - Pedal stop
T screw onto bracket with screw ⇒ item 18 with the master cylinder installed
20 - 25 Nm
T always replace
Clutch control Edition 02.03

30-1 page 2 S00.5317.02.20
Removing and installing the over-centre
helper spring
Removing
– Remove the storage area on the driver's side ⇒ Body
Work; Rep. Gr. 70.
– Remove clutch pedal switch, if provided, ⇒ item 7 in
30-1 page 2.
Unlock the actuating rod/master cylinder from the clutch
pedal as follows:
T10005
– Insert pliers -T10005- in the clutch pedal recesses.
– Compress the support and separate the clutch pedal S30-0051
from the master cylinder.
– Press over-centre helper spring towards the front wall
-in the direction of the arrow- and remove downwards
from the bracket.
S30-0064
Installing
– Insert bearing for over-centre helper spring -arrow 1-
in the bracket.
The peg of the bearing is located in the recess of the mas-
ter cylinder -arrow 2-.
1
S30-0068

S00.5317.02.20
– Insert over-centre helper spring in the bearing.

– Press over-centre helper spring towards the bearing
and position on the support of the clutch pedal -ar-
row-.
– Connect clutch pedal to master cylinder ⇒ 30-1
page 4.
– Installing the clutch pedal switch ⇒ item 7 in 30-1
page 2.
– Install the storage area on the driver's side ⇒ Body
Work; Rep. Gr. 70.
Removing and installing the clutch pedal

S30-0065
Removing
– Remove the over-centre helper spring ⇒ 30-1
page 3
– Unscrew hexagon nut -A- and remove hexagon screw
from bracket.
– Remove clutch pedal.
A
Installing
Installation is performed in the reverse order. Pay atten-
tion to the following points:
S30-0054
– The support -A- must be located on the actuating rod

-B- of the master cylinder.
– To click in the support push the clutch pedal towards
the front wall -direction of the arrow- and make sure it
catches correctly.
B A V30-0419

30-1 page 4 S00.5317.02.20
Summary of components - Hydraulics
1 - Brake fluid reservoir
2 - Tubing
1 2 3 5 6
3 - Master cylinder
⇒ 30-1 page 6
T after installing bleed the
clutch system ⇒ 30-1
page 9
4 - Retaining clip
T to remove the tube-hoseline
⇒ item 9 pull out of the mas-
ter cylinder up to the stop
⇒ 30-1 page 6
5 - Support 4
T only replace if the master cyl-
inder ⇒ item 3 has been re- 16 7
moved
T dismantling ⇒ Fig. 1 in 30-1
page 6 8 8
T push on ⇒ Fig. 2 in 30-1
page 6 9
6 - Clutch pedal 15
12
⇒ 30-1 page 4 10
7 - 28 Nm 11
T always replace 14
12
8 - Sealing ring 13
T fit wetted with brake fluid
9 - Tube-hose line
T assign following spare parts 17 12
catalogue S30-0063
10 - Bracket
T on front left frame side rails
T Clip on tube-hose line ⇒ item 9
11 - Bracket
T holds the tube-hose line ⇒ item 9 on the gearbox
12 - 20 Nm
13 - Bleed valve
T Bleed the clutch system ⇒ 30-1 page 9
14 - Dust cap
15 - Retaining clip
T to remove the tube-hoseline ⇒ item 9 pull out of the slave cylinder up to the stop ⇒ 30-1 page 8
16 - gearbox
17 - Slave cylinder
T after installing bleed the clutch system ⇒ 30-1 page 9

S00.5317.02.20
Fig. 1: Lift off the support -A- in -the direction of

the arrow-.
A
N30-0024
Fig. 2: Push the actuator rod/master cylinder in the

support -A- -direction of the arrow-.
Removing and installing the master cyl-

inder
♦ Pliers -T10005-
Removing
– Disconnect the earth strap from the battery with the ig-
nition off. A N30-0025
– Removing air filter ⇒ 1.9/74 TDI Engine, Fuel Injec-
tion; Rep. Gr. 23
– Remove bracket from the body -direction of the ar-
row-.
– Pull wiring loom towards the front.
S30-0067

30-1 page 6 S00.5317.02.20
– Release and cut off tubing -A- to the brake fluid reser-
voir.
– Remove the retaining clip -B- on the master cylinder
up to the stop.
– Release and cut off the tube-hose line -C- from the
master cylinder. A
– Remove the storage area on the driver's side ⇒ Body
Work; Rep. Gr. 70.
Note
To remove the master cylinder completely remove the
clutch control. Before removing first separate the master
cylinder from the clutch pedal.
S30-0062
Unlock the actuating rod/master cylinder from the clutch

pedal as follows:
– Insert pliers -T10005- in the clutch pedal recesses.

– Compress the support and separate the clutch pedal
from the master cylinder.
T10005
S30-0051

S00.5317.02.20
– Remove clutch pedal switch, if provided ⇒ item 7 in

30-1 page 2.
– Unscrew the hexagon nuts -arrow 1- and remove the
clutch controls -arrow A- together with the master cyl- 1
inder.
– Removing the over-centre helper spring ⇒ 30-1
page 3. 1
– Unhook the bearing/over-centre helper spring from
the bearing.
– Unscrew pedal stop.
– Remove the master cylinder.
1
A
Installing
S30-0052
– The support -A- must be located on the actuating rod

-B- of the master cylinder.
– To click in the support push the clutch pedal towards
the front wall -direction of the arrow- and make sure it
catches correctly.
– After installing the master cylinder bleed the clutch
system ⇒ 30-1 page 9.
Removing and installing the slave cylin-

der
Removing
– Remove the engine cover. B A V30-0419
– Before disconnecting the battery determine the code

of vehicles equipped with anti-theft coding.
nition off.
– Remove battery and battery console ⇒ Electrical Sys-
tem; Rep. Gr. 27.
– Removing air filter ⇒ 1.9/74 TDI Engine, Fuel Injec-
tion; Rep. Gr. 23 4
– Remove the shift cable with the gearbox shift lever -2-,
for this step unscrew nut -1-. 3
– Detach selector cable with the relay lever -4-, for this
step remove circlip -3- from the relay lever.
2
1 S34-0501

30-1 page 8 S00.5317.02.20
– Release screws -1- from the Bowden cable support. 1
– Lay Bowden cable support to the side and tie up.
4
– Pull out the retaining clip -2- up to the stop and subse-
quently the tube-hose line -3- from the slave cylinder,
cut off the line. 1
– Pull tube-hose line -3- from the holder -4- on the gear-
box. 1 3
5
Note 2
Do not depress the clutch pedal.
– Unscrew the screws -5- for the slave cylinder.

– Remove the slave cylinder from the top. While doing S34-0502
so press the tappet end slightly into the slave cylinder.
Installing
– Grease tappet end with MoS2-grease. 1

– Screw the slave cylinder to the gearbox -5-. 4
– Insert tube-hose line -3- into the slave cylinder.
– Press retaining clip -2- up to the stop, and check lock- 1
ing of tube-hose line.
– Press the tube-hose line into the holder -4-. 1 3
– After installing the slave cylinder bleed the clutch sys- 5
2
tem ⇒ 30-1 page 9.
– Installing Bowden cable support, relay lever and gear-
shift lever ⇒ Chapter 34-5.
– Installing air filter ⇒ 1.9/74 TDI Engine, Fuel Injection;
Rep. Gr. 23. S34-0502
Torque
Component Torque
Slave cylinder on gearbox 20 Nm
Bleeding the clutch system

♦ Brake filling and bleeding device -ROMESS S15-
Brake fluid specification ⇒ Running Gear; Rep. Gr. 47.

A
– Connect the brake filling and bleeding device
-ROMESS S15-.
– Insert the bleeder hose -A- on the slave cylinder -ar-
row- and open the bleeder valve.
– Activate system with a pressure of 2 bar.
S30-0069

S00.5317.02.20
– Allow approx. 100 cm3 of brake fluid to flow out until

no more air bubbles are visible.
– Shut the bleeder valve.
– Activate pedal forcefully from stop to stop between 10
and 15 times.
– Open the bleeder valve.
– Again allow approx. 100 cm3 brake fluid to flow out.
– Shut the bleeder valve.
– After completing the bleeding procedure activate the
clutch pedal repeatedly.
– Disconnect brake filling and bleeding device.

30-1 page 10 S00.5317.02.20
30-2 Repair of the clutch control

Special tools, test and measuring equipment and aids required
♦ Grease MoS2
♦ Sealing grease -G 052 128 A1-
1 - Gearbox
2 - Ball stud, 25 Nm
T grease with grease MoS2
11 10 10 9
3 - Gasket ring for drive shaft
T fitted in guide bushing
⇒ item 4
T replacing ⇒ Chap. 34-10
T fill half the space between
the sealing lips with sealing
grease -G 052 128 A1-
4 - Guide bushing with O-ring
T with gasket ring for drive
shaft
T O-ring is fitted to guide bush-
ing
T if damaged replace O-ring
and guide bushing ⇒ Chap.
34-10
T before removing, remove
clutch release lever ⇒ item 7
T grease with grease MoS2 in
the area of the clutch release
bearing
5 - Retaining spring
T attach to clutch release lever
6 - 18 Nm
7 - Clutch release lever
T ⇒ item 8 remove and install
⇒ Fig. 1 in 30-2 page 2 to- 1 2 3 4 5 6 7 8
gether with clutch release
bearing
S30-0071
8 - Clutch release bearing
T Do not wash the bearing only wipe it clean
T replace noisy bearing
T removing and installing ⇒ Fig. 2 in 30-2 page 2
T grease contact points on the clutch release lever with grease MoS2
9 - Slave cylinder
T removing and installing ⇒ Chap. 30-1
T grease tappet end with grease MoS2
10 - 20 Nm
11 - Mounting bolt
T secures the clutch release lever when installing the gearbox ⇒ Chap. 34-7
T unscrew after the gearbox has been fitted
Note
If a mounting bolt is not provided, use bolt M8 x 35.
Edition 07.00 Repair of the clutch control 30-2 page 1

S00.5317.00.20
Fig. 1: Remove and install the clutch release lever

together with the clutch release bearing and
guide bushing
Removing
– Unhook spring -arrow 1- upwards. 2

– Remove clutch release lever -arrow 2- from ball stud.
Installing
– First mount spring -arrow 1- on the clutch release le-

ver. 1
– Press clutch release lever -arrow 2- onto the ball stud.
S30-0070
Fig. 2: Removing and installing the clutch release

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

the clutch release bearing -A- from the clutch release
lever.
– To install press clutch release bearing -A- into the
clutch release lever until the catch pegs -arrows- lock
into position.
Repair of the clutch control Edition 07.00

30-2 page 2 S00.5317.00.20
30-3 Repairing the clutch

♦ Counterholder -MP 1-223-
♦ Centering mandrel -MP 3-475-
♦ Grease -G 000 100-
(Gearbox removed)
Note
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ Make the clutch disc and pressure plate coincide in accordance with the spare part catalogue and engine identifi-
cation characters.
1 - Flywheel
T make sure the centering pins
are tight
T The locating face for the
clutch lining must be free
from grooves, oil and grease
⇒ Rep. Gr. 13; the relevant
engine, flywheel removing
and installing
2 - Clutch disc
T Diameter ⇒ Chap. 00-1
T Fitting position: the spring
cage pointing towards the
pressure plate
T center ⇒ Fig. 1 in 30-3
page 2
T slightly grease the serration
Note
♦ Clean the serration on the
drive shaft and if the clutch
discs have been used clean
the hub serration, remove
corrosion and only apply a
very thin layer of grease SP
No.: G 000 100 on the drive
shaft serration.
♦ Subsequently move the
clutch disc up and down on
the drive shaft until the hub
fits smoothly on the shaft.
♦ Remove all excess grease.
3 - Pressure plate
T Check the extremities of the membrane spring ⇒ Fig. 2 in 30-3 page 2
Note
The pressure plates are protected against corrosion and are greased. Only clean the thrust surface as otherwise
the life of the clutch may be considerably reduced.
4 - 20 Nm
T assign following spare parts catalogue
T Release or tighten gradually and crosswise
Edition 07.00 Repairing the clutch 30-3 page 1

S00.5317.00.20
Fig. 1: Center the clutch disc and remove and in-

stall the pressure plate
– release or tighten gradually and crosswise.

– When removing inverse theposition of the pressure
pad -MP 1-223-.
Note
♦ The thrust surface of the pressure plate and the clutch
disc lining must fully rest against the flywheel.
♦ Tighten the fixing screws crosswise and uniformly so
as not to damage the centering holes on the pressure
plate and the centering pins of the flywheel.
Fig. 2: Check the extremities of the membrane

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

ness.
Repairing the clutch Edition 07.00

30-3 page 2 S00.5317.00.20
34 – Control/Housing
34-1 Shift mechanism
Fitting location of shift mechanism

Arrow A - Shift movement
Arrow B - Selector movement
A - Shift cable for shift movement

B - Selector cable for selector
movement 5 4
C - Heat shield 3 2
1
T take off before removing the R
shift mechanism
1 - Gearshift lever
B
2 - Reversing lever
A
A
2
B
B
A C
S34-0488
Edition 02.03 Shift mechanism 34-1 page 1

S00.5317.02.20
Note
♦ Disconnect earth strap at battery before carrying out work on the shift mechanism in the engine compartment.
♦ Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;
Rep. Gr. 27.
♦ Remove shift mechanism for replacing control cables ⇒ Chapter 34-5.
♦ Do not buckle the control cables.
I - Summary of components -
gearshift knob and cover
⇒ Chapter 34-2
II - Summary of components -
shift lever and shift housing
⇒ Chapter 34-3
III - Summary of components -
control cables ⇒ Chapter 34-
4
Removing and installing shift
mechanism ⇒ Chapter 34-5
Setting shift mechanism
⇒ Chapter 34-6
Shift mechanism Edition 02.03

34-1 page 2 S00.5317.02.20
34-2 I - Summary of components - gearshift knob and cover

1 - Gearshift knob I
T with collar
T the gearshift knob and collar
cannot be separated
T always replace together
⇒ 34-2 page 2
1
2 - Collar clamp
T for securing the gearshift
knob to the gearshift lever
3 - Surround of centre console
S34-0485
Edition 07.00 I - Summary of components - gearshift knob and cover 34-2 page 1
S00.5317.00.20
Separating collar from gearshift lever

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

er with the collar.
Installing
– Turn collar inside out.
– Insert gearshift knob and collar and compress collar
clamp -arrow-.
When inserting the gearshift knob on the selector lever
the gearshift knob must lock into the round slot of the
gearshift lever.
I - Summary of components - gearshift knob and cover Edition 07.00

34-2 page 2 S00.5317.00.20
34-3 II - Summary of components shift lever and shift housing
Note
Grease bearing and friction surfaces with polycarbamide grease -G 052 242 A2-.
1 - Lock washer II
T removing and installing 1
⇒ Fig. 1 in 34-3 page 2 2
2 - Bush
3 - Pressure spring 3
4 - Bush 4 11
5 - 5 Nm 5 5
6 - Cover
7 - Bearing shell 6
8 - Damping
9 - Shift lever guide 7
10 - Insulating washer 12
11 - Gasket 8
27
T between shift housing and
body 9 26 13
T adhesive 25 14
T stick onto shift housing
10 15
12 - Shift lever
13 - Insulation
14 - Shift housing 24
16
15 - Bearing bush 23
16 - Bearing pin 17
17 - Guide bush 12 18
18 - Pressure spring
T installing ⇒ Fig. 2 in 34-3 22 19
page 2
19 - Selector lever
21 20
20 - 5 Nm
21 - Floor plate S34-0486
T bend up tabs for removing
T replace
22 - Selector cable
T at selector angle plate
T Fitting location ⇒ Chap. 34-1
23 - Shift cable
T press onto shift lever guide
24 - Circlip
25 - 25 Nm
T 4 pieces
26 - Bearing bush
T fits in one position only
27 - Circlip
Edition 07.00 II - Summary of components shift lever and shift housing 34-3 page 1
S00.5317.00.20
Fig. 1: Removing and installing circlip
– To remove and install the circlip -arrow A- press spac-

er bush -arrow B- with screwdriver up to the stop in the
direction of the arrow -arrow C- and remove circlip.
Note C
♦ Do not twist bush when pressing down.
♦ Mounting slot in shift lever for circlip must be visible.
A
♦ Release spring carefully.
B
N34-1363
Fig. 2: Installation of pressure spring
– Insert pressure spring so that leg -A- is positioned

above the stud -arrow-.
– After this, pull the leg -B- down far enough so that it
moves underneath the stud -arrow-.
II - Summary of components shift lever and shift housing Edition 07.00

34-3 page 2 S00.5317.00.20
34-4 III - Summary of components - Control cables
Note
Grease bearing and friction surfaces with polycarbamide grease -G 052 242 A2-.
1 - Shift cable III

T pressed onto shift lever
guide
1 3
2 - Selector cable
T at selector angle plate
3 - Circlip 4
4 - Shift housing
2 5
5 - Circlip
T do not damage cables when
removing
6 - 20 Nm
1
T 3 pieces
T for support
7 - Support
8 - Grommet
2
T mounting of support to gear-
box 5 6 5
9 - Spacer 12 10
10 - Cable lock
T for selector cable
11 - Cable lock 13
T for shift cable 14 7
12 - Relay lever
11 8 8
T Fitting position ⇒ Fig. 1 in
34-4 page 2 15
13 - Sliding shoe
14 - 20 Nm 9
15 - Gearshift lever S34-0487
T with balancing weight
T insert in such a way that the interrupted tooth-pitch is opposite the gearshift shaft
T after installing set shift mechanism ⇒ Chap. 34-6
T Fitting position ⇒ Fig. 1 in 34-4 page 2
Edition 11.00 III - Summary of components - Control cables 34-4 page 1

S00.5317.01.20
Fig. 1: Fitting location of gearbox shift lever/relay

lever
1 - Gearbox shift lever with balancing weight 2
2 - Relay lever is inserted over the sliding shoe into the
sliding rail of the gearbox shift lever -arrow-
S34-0476
III - Summary of components - Control cables Edition 11.00

34-4 page 2 S00.5317.01.20
34-5 Removing and Installing

Shift Mechanism
Removing
A
– Disconnect the earth strap from the battery with the ig- B
nition off.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
1
– Use an open-end wrench to lever off selector cable 2
-A- and shift cable -B- at gearbox.
S34-0480
1 - Open-end wrench waf 13
2 - Pliers
– Remove Bowden cable support -arrows-.
S34-0477
– Lever the collar out of the surround of centre console

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

S00.5317.01.20
– Open clamp -arrow- and pull off gearshift knob togeth-

er with the collar.
– Removing the centre console ⇒ Body Work;
Rep. Gr. 68.
– Unscrew nuts -arrows- attaching the shift housing.
S34-0499
– Detach bracket -1- below the exhaust system.

– Unhook exhaust pipe from bracket -2-.
2
– Unbolt bracket for exhaust pipe -2-.
– Separate exhaust system at the double clamp -3-.
– Unbolt bracket -4- for front silencer.
– Remove heat shield -5-.
– Swivel shift housing down and remove with control ca-
bles.
3
Installing
The installation occurs in reverse order, while paying at-
tention to the following:
– Assemble exhaust system free of stress ⇒ 1.9/74 kW 1

Engine - Mechanics; Rep. Gr. 26.
– Pay attention to the fitting location of the strut -1-.
4 5
S34-0489
Removing and Installing Shift Mechanism Edition 11.00

34-5 page 2 S00.5317.01.20
– Pack a small quantity of polycarbamide grease into
the ball socket of the shift cable lock -A- and of the se-
lector cable lock -B-.
Note
The seals -arrows- outside the ball socket must be free of
grease.
– Press the shift cable onto the gearshift lever and the
selector cable onto the relay lever -arrows-.
Setting shift mechanism ⇒ Chap. 34-6.
Tightening torques
Components Torque
Shift housing to body 25 Nm
Strut to body 25 Nm
Cable support to gearbox 20 Nm
Bracket to body 25 Nm
S34-0478
Edition 11.00 Removing and Installing Shift Mechanism 34-5 page 3

S00.5317.01.20
Removing and Installing Shift Mechanism Edition 11.00

34-5 page 4 S00.5317.01.20
34-6 Setting shift mechanism

♦ Rig pin -T10027-
Note 1
♦ The following points are requirements for correct set-
ting of the shift mechanism:
♦ Operating and transmission elements of the shift
2
mechanism are in proper condition. 1
♦ Shift mechanism operates freely.
♦ Gearbox, clutch and clutch control must be in proper 2
condition.
• Gearbox in Neutral.
– Pull locking mechanism at shift cable and at selector
cable forward as far as the stop -arrow 1- and then
lock by turning to the left -arrow 2-. S34-0479
Lock the shift shaft as follows:
– Press the shift shaft down -direction of arrow 1-.

– When pressing down the shift shaft, press the angle
lever -A- slightly towards the shift shaft and then turn
the angle lever in the direction of -arrow 2-
1
2
S34-0482
A
Edition 07.00 Setting shift mechanism 34-6 page 1

S00.5317.00.20
– Lever the collar upwards and out of the surround of

centre console -arrows-.
– Guide shift lever in Neutral to the left into the gate of
1st/2nd gear.
– Insert locking pin -T10027- through hole -A- into hole

-B-.
– Now turn the locking mechanism at the shift cable and

at the selector cable to the right as far as the stop -ar- 2
row 1-.
The spring pushes the locking mechanism into the initial
position -arrow2-. 1
2
S34-0484
Setting shift mechanism Edition 07.00

34-6 page 2 S00.5317.00.20
– Now turn the angle lever -A- back into the initial posi-
tion -direction of the arrow-.
S34-0481
A
– Pull the locking pin -T10027- out of the hole -A- and
-B-.
– Fit collar into the surround for centre console.
Operation
• Shift lever must be positioned in Neutral in the gate of
3rd/4th gear.
– Depress clutch.
– Shift through all gears several times. Pay particular at-
tention to proper operation of the reverse gear lock.
If the gearshift lever catches when repeatedly engaging a
gear, check the play (stroke) of the shift shaft as follows:
– 1. Engage 1st gear.

– Push shift lever fully to the left and release again.
– At the same time, observe the shift shaft at the gear-
box (2nd mechanic).
– When the gearshift lever is moved, the shift shaft must
make a stroke of about 1 mm -direction of arrow-.
– If this is not the case, set shift mechanism ⇒ Chap.
34-6.
S34-0483
Edition 07.00 Setting shift mechanism 34-6 page 3

S00.5317.00.20
Setting shift mechanism Edition 07.00

34-6 page 4 S00.5317.00.20
34-7 Removing and installing

the gearbox
Removing
♦ Gearbox mount -3282-
♦ Adjusting plate -T30020-
♦ Engine and gearbox jack (e.g. -V.A.G 1383 A-)
♦ Transport device -MP 3-478-
♦ Supporting device -MP 9-200-
♦ Grease -G 000 100-

nition off.
4
– Remove the engine trim panel.
– Remove air filter box completely with air guide hose 3
⇒ 1.9/74 TDI Engine - Fuel Injection; Rep. Gr. 23.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27. 2
– Remove the shift cable with the gearbox shift lever -2-,
for this step unscrew nut -1-. 1 S34-0501
– Detach selector cable with the relay lever -4-, for this
step remove circlip -3- from the relay lever.
– Disconnect cable support -arrows-, lay aside and tie
up. C
– Draw out the tube and hose line -A- from bracket -C-
on the gearbox.
– Remove the slave cylinder -B- and lay aside, secure
with wire, do not open the line system. A
– Unscrew bracket -C- for tube and hose line from the
gearbox.
B
Note
Do not depress the clutch pedal.
S34-0475
Edition 02.03 Removing and installing the gearbox 34-7 page 1

S00.5317.02.20
– Release and disconnect connector -arrow 1- from the

starter and connector -arrow 2- from reversing light
switch -F4-.
– Lever off protective cap and unscrew cable -arrow 3-
from the starter.
2
S34-0491
– Unplug connector -arrow- from speedometer sender

-G22-.
– Remove engine/gearbox connecting screws at the
top.
– Release securing screws for starter at the top.
– Remove front left wheel and raise vehicle.
– Remove noise insulation panel -arrows-.

– Removing front exhaust pipe with catalytic converter
⇒ 1.9/74 TDI Engine - Mechanics; Rep. Gr. 26.
S10-0114
Removing and installing the gearbox Edition 02.03

34-7 page 2 S00.5317.02.20
– Unscrew bracket from starter -arrow- and lay aside to-
gether with lines.
– Remove the starter ⇒ Electrical System; Rep. Gr. 27.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66; Wheelhouse liner.
– Unscrew shield for inside right steering joint boot.
– Disconnect the drive shafts from the flange shafts,
turn steering wheel to the left.
S34-0492
– Mark installation position of bolts -1- for left steering

joint, otherwise the steering geometry must be
checked.
– Release screws -1-.
– Unbolt coupling rod -2- from the anti-roll bar -arrow-.
– Turn coupling rod upwards.
– Swivel out the wheel-bearing housing.
– For this step guide the drive shaft into the wheelhouse
and secure to the suspension strut with e.g. wire.
– Tie up the right drive shaft as far as possible. Avoid
damaging the paintwork on the drive shaft during this
operation.
– Unbolt the pendulum support -arrows 1 and 2-.

1
– Unscrew the engine/gearbox connecting screw above
the right flange shaft.
Note 1
When installing the pendulum support position the
screws -1- in the elongated holes of the pendulum sup-
port in such a way that there is maximum distance be-
tween the gearbox and the assembly carrier.
2 S34-0528

S00.5317.02.20
– Remove small cover plate -A- for flywheel behind the

right flange shaft -arrows-.
V34 - 3005
– Remove the support for the engine cover in the left lift-
ing eye of the engine -arrow-
S34-0493
– Install supporting device -MP 9-200-.
Note
When installing the lifting hooks of the supporting device,
pay attention to hose and cable connections in the area
of the lifting eyes of the engine to avoid damaging them.

34-7 page 4 S00.5317.02.20
– Take up the weight of the engine/gearbox unit at the
spindles.
– Remove the plug from the expansion reservoir for
coolant.
– Unscrew coolant expansion reservoir and lay aside,
do not open cooling system.
– Completely unscrew engine mounting -arrows-.
– Unscrew the fixing screws -arrows- from the gearbox

mount.
Remove the fixing screws -arrows- for the gearbox

mounting bracket as follows:
A
– Lower engine/gearbox unit sufficiently at the two spin-
dles until the fixing screws attaching the gearbox
mounting bracket -A- are accessible from the left
wheelhouse.
– Detach gearbox mounting bracket -A- from the gear-
box.
Note
When lowering the engine/gearbox unit, make sure the
gearbox does not touch the assembly carrier.
– Insert engine/gearbox mount -3282- into engine/gear- S34-0494

box jack, e.g. -V.A.G 1383 A-.
Complete engine/gearbox jack with gearbox mount
-3282-, adjusting plate -T30020- for „02R“ gearbox and
the support elements as follows:
– Position adjusting plate -T30020- on gearbox mount

-3282- (adjusting plate fits in only one position).
– Align arms of the gearbox mount to match the holes in
the adjusting plate.

S00.5317.02.20
– Screw in the mounting elements -A- and -C- as shown

on adjusting plate.
A
– Screw in the bolt -3282/29-, as indicated on the ad-
justing plate.
C
T3
00
20
A
32
82
/2 9
B S34-0520
– Position engine/gearbox jack below vehicle, arrow

-symbol B- (S34-0520) on adjusting plate points in the
direction of travel/vehicle.
– Align adjusting plate parallel to the gearbox and lock
securing mounts at gearbox.
– Remove the bottom fixing screws for the engine/gear-
box. 3282/29
– Press gearbox off the engine and swivel towards the
assembly carrier. T30020
– Via the spindles swivel the gearbox backwards and
down towards the assembly carrier.
– After this lower gearbox carefully.
– Change the gearbox position at the spindles of the 3282 S34-0495
gearbox mount -3282- when lowering.
Note
♦ When removing the gearbox -1- ensure the gearbox 1
does not touch the subframe -2- -arrows-.
♦ When lowering guide the coolant hoses past the gear-
box. 2
S34-0496

34-7 page 6 S00.5317.02.20
Transporting the gearbox
– Screw down gearbox suspension device -MP 3-478-
onto clutch housing.
MP 3-478
S34-0183
– Adjust supporting arm at slide with locking pin -arrow-.

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

pension device -MP 3-478-.
– Place down gearbox, e.g. in a transport container.
Installing
MP 3-478
– Before installing, unscrew plug for gearbox oil inspec-
tion and pour in gear oil.
Capacity and specification ⇒ Chapter 00-1.
The installation of the gearbox occurs in reverse order. S34-0184
Install engine/gearbox mounting free of stress
⇒ Rep. Gr. 10; of the relevant engine.
– If the gearbox is replaced, if provided always replace

the speedometer sender (Fig.), gearshift lever
(⇒ Chapter 34-3) and relay lever.
V90-0815

S00.5317.02.20
– Before installing the gearbox press the clutch release

lever towards the gearbox housing and secure with
mounting bolt or screw M 3 x 35.
– After installing the gearbox release screw again. The
hole is then closed by the 3 fixing screws for the sup-
port/control cables.
Note
♦ Clean splines of drive shaft and apply a thin film of
grease -G 000 100-.
♦ The clutch plate must slide freely up and down the
drive shaft.
♦ If the gearbox is replaced, ensure the intermediate
plate between the engine and gearbox is correctly in- V34-2678
stalled.
♦ Check whether the dowel sleeves for centering the
gearbox are present in the cylinder block; insert if nec-
essary.
♦ Install engine mounting ⇒ 1.9/74 Engine - Mechanics;
Rep. Gr. 10.
♦ Assemble exhaust system free of stress ⇒ 1.9/74 kW
Engine - Mechanics; Rep. Gr. 26.
♦ Installing starter and cable ⇒ Electrical System;
Rep. Gr. 27.
♦ Inspecting gear oil ⇒ Chapter 34-8.
♦ Setting shift mechanism ⇒ Chapter 34-6.
2
♦ Install ⇒ Electrical System; Rep. Gr. 27.
♦ If the battery earth strap is disconnected and connect-
1 3
ed, carry out additional operations ⇒ Electrical Sys-
tem; Rep. Gr. 27.
Tightening torques A
3
Pos. Screw Qty Nm
1 M12 x 55 2 80
21) M12 x 55 1 80 4
4
31) M12 x 150 2 80
4 M10 x 55 3 45 A 1 S34-0497
1) Screw with threaded pin M8
A: Dowel sleeves for centering
Hinged bracket
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
1
1 - 30 Nm + 90° (1/4 turn) - replace
2 - 40 Nm + 90° (1/4 turn) - replace
Drive shaft to flange shaft ⇒ Running Gear; Rep. Gr. 40

2 S10-0133

34-7 page 8 S00.5317.02.20
Components Torque
Gearbox mounting bracket to gear-
40 Nm + 90°
box1) M10
Gearbox mounting bracket to gear-
40 Nm + 90°
box mount1) M10
Protective cap drive shaft on engine 35 Nm
Cable support to gearbox 20 Nm
Gearbox shift lever to gearbox 20 Nm
Slave cylinder on gearbox 20 Nm
Steering joint to front track control
20 Nm + 90°
arm1) M8
Coupling rod to anti-roll bar 40 Nm
Wheel bolts to wheel hub 120 Nm
Nut for attaching double clamp of ex-
40 Nm
haust system
1) Always replace these bolts

S00.5317.02.20

34-7 page 10 S00.5317.02.20
34-8 Inspecting gear oil

Gear oil specification ⇒ Chap. 00-1
– Removing noise insulation ⇒ Chap. 34-7.

– Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
– Tighten plug -arrow-, 30 Nm.

When re-filling, pay attention to the following points:
– Unscrew plug -arrow-.

– Pour in gear oil up to lower edge of filler hole.
S34-0498
– Screw in plug -arrow-.
– Start engine, engage a gear and allow gearbox to ro-
tate for about 2 minutes.
– Switch off engine, unscrew plug -arrow- and again top
up gear oil to lower edge of filler hole.
– Tighten plug -arrow-, 30 Nm.
– Installing noise insulation ⇒ Chap. 34-7.
Edition 07.00 Inspecting gear oil 34-8 page 1

S00.5317.00.20
Inspecting gear oil Edition 07.00

34-8 page 2 S00.5317.00.20
34-9 Disassembling and assembling the gearbox

Mounting sequence ⇒ 34-9 page 4
I - Disassembling and assem-

bling gearbox housing cover II I
and 5th gear ⇒ 34-9 page 2
II - Disassembling and assem-
bling gearbox housing and
gearshift mechanism ⇒ 34-9
page 3
III - Disassembling and assem-
bling the drive shaft, output
shaft, differential and gear-
shift forks ⇒ 34-9 page 4
III
S34-0507
Edition 07.00 Disassembling and assembling the gearbox 34-9 page 1

S00.5317.00.20
I - Disassembling and assembling gearbox housing cover and 5th gear

1 - 14 Nm
2 - Cover for gearbox housing
1
Note
If the gearbox housing cover is 2
fitted with the gearbox mounted,
inspect the oil level and top up 3
with gear oil ⇒ Chap. 34-8.
3- Gasket
4- Inside Torx screw M10, 80 Nm
4
T holds disc spring in position
with sleeve socket on screw 5
head
5- Disc spring
T installing ⇒ 34-9 page 14
6- Fillister head screw, 25 Nm 6
T for bearing pins on the gear-
box housing
9 7
7- Bearing pins
10 8
8- 5th gear shift fork
4
T disassembling and assem-
bling ⇒ Chap. 34-12 5
11 6
T adjust ⇒ 34-9 page 15
9- Spring 7
10 - 5th gear sliding sleeve 12
11 - Arresters (3 pieces)
12 - Synchronizer body with slid-
14
ing gear and synchronizer 13
ring for 5th gear
bling ⇒ Chap. 35-1 S34 - 0504
T removing ⇒ 34-9 page 6,
Fig V34-2312
13 - Needle bearing
T dimension 35 x 40 x 23.8
14 - Gear pinion for 5th gear
T Fitting position ⇒ 34-9 page 12
Disassembling and assembling the gearbox Edition 07.00

34-9 page 2 S00.5317.00.20
II - Disassembling and assembling gearbox housing and gearshift mechanism
♦ Sealant -AMV 188 200 03-
1 - Conical screw, 25 Nm
2 - Flange shaft with pressure 1 2 3 4 5 6 7 6 8 9
spring
⇒ 34-9 page 4
T complete ⇒ Chap. 39-2
3 - 25 Nm
T M8 x 26
T for reverse shaft support
4 - 30 Nm
12
T for reverse shaft support
T M8 x 32 5
5 - Sealing ring
10
T always replace
6
6 - Bearing pins
7 - 22 Nm
8 - 22 Nm
9 - End cover 7
10 - Gearbox housing
T repairing ⇒ Chap. 34-10 6
11 - Clutch housing
11
T repairing ⇒ Chap. 34-10 14
12 - turn 25 Nm and 90°
T for attaching the gearbox
housing to the clutch housing
13 - Shift mechanism 13
bling
14 - 22 Nm 12
S34-0505

S00.5317.00.20
III - Disassembling and assembling the drive shaft, output shaft, differential and
gearshift forks
1 - Differential
T disassembling and assem- 1 2 3 4 5 6 7 8 9
bling ⇒ Chap. 39-2
2 - Gasket ring
T 4 pieces
T always replace
3 - Output shaft
4 - reverse shaft support
5 - Reverse shaft
6 - Drive shaft
7 - Gearshift fork reverse gear
T disassembling and assem- 10
T Fitting position ⇒ 34-9
page 4
8 - 25 Nm
9 - Shift mechanism
T (Gearshift forks)
10 - Clutch housing
T repairing ⇒ Chap. 34-10 13 12 11
S34-0506
11 - turn 25 Nm and 90°
T 4 nuts for bearing support
12 - Flange shaft with pressure spring
T complete ⇒ Chap. 39-2
13 - Conical screw, 25 Nm
Mounting sequence
Disassembling and assembling the gearbox housing
cover, gearbox housing, shift mechanism, drive
shaft, output shaft, differential and gearshift forks

♦ Driver -MP 1-304-
♦ Drive bushing -MP 3-402-
♦ Gearbox mount -MP 3-501-
♦ Assembly stand -MP 9-101-
♦ Two-arm extractor -Kukko 20/10-

34-9 page 4 S00.5317.00.20
♦ Extraction hook -Matra V/170-
♦ Hot-air blower (e.g. -V.A.G 1416-)
♦ Studs -M8 x 100-
♦ Feeler gauge
♦ Sealant -AMV 188 200 03-
Disassembling
– Position catch pan beneath.
– Drain gear oil, to this end unscrew oil drain plug -ar-
row-.
S34-0156
– Secure gearbox to the assembly support -arrows-.

– Removing the clutch release lever, clutch release 1
bearing and guide bushing ⇒ Chap. 30-2.
– Unscrew the cover -1- for the gearbox housing.
MP 9-101
MP 3-501 S34-0310
Remove shift fork and 5th gear sliding sleeve as follows:

3 4
2 2
A A
B S34-0511

S00.5317.00.20
– Put shift fork -1- in Neutral position.

– Release screw -2- for bearing pins.
A 1
– Remove bearing pins -arrows A-.
– Guide shift fork out of shift rail -arrow B-.
– Remove spring -3-.
– Carefully pull off sliding sleeve -4-, and also remove
locking elements.
– Put the sliding sleeve without shift fork back onto the
synchronizer body.
3
– Release nuts -A- for the synchronizer body and 5th
gear pinion, while engaging the 5th gear -arrow 1- and
1st gear -arrows 2 and 3-.
N34-0927
– The input and output shafts are blocked after introduc- 2
ing the two gears, the synchronizer body and pinion
cannot rotate. Now it is possible to release the two
bolts.
– Remove the 5th gear sliding sleeve. A
– Pull off synchronizer body with 5th gear sliding gear
and remove with needle bearing.
A - Two-arm extractor e. g. -Kukko 20/10- with hook
-Matra V/170- B
B - Hexagon screw M10 x 20
V34 - 2312
– Remove gear pinion for 5th gear.
Note A
♦ When pulling off the gear pinion make sure the hooks
do not bend outwards, if necessary tighten screw -ar-
row-.
♦ Check 5th gear for damage after removing.
A - Two-arm extractor e. g. -Kukko 20/10- with hook

B
-Matra V/170-
B - Hexagon screw M10 x 20
Mounting sequence:
♦ Set up two-arm extractor and centre by turning the
S34-0524
screw -arrow-.
♦ If necessary heat pinion with hot-air blower (e.g.
-V.A.G 1416-) and remove with two-arm extractor.

34-9 page 6 S00.5317.00.20
– Remove left flange shaft, use drift to secure against
turning and unscrew conical screw -arrow-.
N34 - 0109
– Remove both screws -arrows- for support/reverse

shaft.
– Remove the gearshift shaft with cover, to this end put V34-2007
the gearshift shaft in neutral position.
– Subsequently unscrew screws -arrows- and remove
the gearshift shaft from the gearbox housing by lever-
ing off the gearshift cover.
N34-0928

S00.5317.00.20
– Remove screws -arrows- from the cap -A- and the

bearing pins -B- at the bottom of the gearbox.
B
A
MP 3-501 S34-0500
– Carefully remove the cap -A- with driver -MP 1-304-

and hammer -B-.
A
B
MP 1-304
S34-0523
– Remove bearing pins -A- on the top side of the gear-

box and fixing screws -B- for the gearbox housing on
the clutch housing near the differential gear. B A
V34-2615

34-9 page 8 S00.5317.00.20
– Release screws -A-, that serve to secure the gearbox
housing from the clutch housing. MP 3-501
A
Note
Do not release nuts -B- for the output shaft bearing sup-
port.
S34-0135
– Carefully release the gearbox housing from the pro-

jecting housing lands -arrows- and make sure the
sealing surfaces are not damaged in the process.
V34-2618
– Remove shift forks -A- together with shift rails.

– Unscrew shift mechanism/reverse gear -B-.
V34-2619
B

S00.5317.00.20
– Release nuts -B- for the bearing support/output shaft.

MP 3-501
A
S34-0135
– Successively remove the reverse gear -A-, drive shaft

-B- and output shaft -C- from the clutch housing.
B C
– Remove right flange shaft and take out differential
gear.
Assembling
V34-2620
– Insert the differential gear.
– Always replace gasket rings -arrows- for bearing sup-
port/output shaft.
Note
The fig. only shows 3 of the 4 gasket rings.
– Replace the drive shaft, output shaft and reverse shaft

together.
– Tighten nuts for the bearing support/output shaft to 25
Nm and turn a further 90°.
– Remove locking agent from the thread in the reverse
shaft support. Clean with a screw-tap.
– Insert reverse shaft support.
V34-2653
– Mount shift mechanism/reverse gear and tighten fix-
ing screw to 25 Nm.

34-9 page 10 S00.5317.00.20
Fitting location of reverse gear
V34-2012
– Mount shift forks together with shift rails.
– Screw the studs -A- M8 x 100 in the reverse shaft sup-
port, to ensure it is aligned once the gearbox housing
has been fitted.
– Align shift rails. A
Note
The shift segments must be positioned in the slots of the
sliding sleeves.
– Apply sealant -AMV 188 200 03- uniformly on the

sealing surface.
– Fit gearbox housing and tighten fixing screws to 25
S34-0314
Insert the screws for the reverse shaft support -arrow- as
follows:
– Insert screw -a-, release stud, mount screw -b- and

tighten by hand.
Tightening sequence:
1 - Screw -a- 30 Nm (M8 x 32)
2 - Screw -b- 25 Nm (M8 x 26)
b
a V34-2293

S00.5317.00.20
– Fit bearing pins -arrow- for shift fork. Align the shift
mechanism with a screwdriver to ensure the relevant
bearing pin can be fitted.
sealing surface of the cap.
– Fit shift shaft cap and tighten screws to 22 Nm.
V34 - 2009
Install the gearshift shaft as follows:
– Put the shift rails in neutral position.

2
– Position the peg -arrow 1- in the recess of the gearbox
housing. Align the gearshift shaft in such a way that
the shift finger -arrow 2- is inserted in the shift rails.
sealing surface of the cover.
– Fit shift shaft cover and tighten screws to 22 Nm.
1
V34 - 2006
Fitting position of the 5th gear pinion

The round slot -arrow- points to the gearbox housing
V34-2654

34-9 page 12 S00.5317.00.20
– Heat pinion to approx. 100°C.
– Drive in 5th gear pinion
MP 3-402
S34-0137
Checking 5th gear synchronizer ring for wear
– Before refitting the 5th gear sliding gear and synchro-
nizer ring, press the synchronizer ring on the cone of
the sliding gear and measure the clearance -a- with a
feeler gauge.
Fitting dimen- Wear limit

sion
Clearance -a- 1,1 ... 1.7 mm 0.5 mm
a
– Install the 5th gear sliding gear with needle bearing.
– Position the 5th gear synchronizer ring on the sliding
gear.
– Assemble the 5th gear synchronizer body/sliding
sleeve before installation ⇒ Chap. 35-1 V35-1125
Fitting position of 5th gear synchronizer body/

sliding sleeve 2
The sharp teeth of the sliding sleeve -arrow 1- and the
high collar of the synchronizer body -arrow 2- point to-
wards the gearbox housing.
The supports -arrow 3- of the synchronizer body are on
the same line as the integrated arresters of the synchro- 1
nizer ring (arrows in Fig. N35-0018 ⇒ 34-9 page 14. 3
N34 - 0059

S00.5317.00.20
5th gear synchronizer ring with integrated ar-

resters -arrows-
N35 - 0018
– Heat synchonizer body to approx. 100°C.
– Drive in 5th gear synchronizer body/sliding sleeve.
Note
Pay attention to the free travel of the synchronizer ring MP 3-402
during the driving in operation.
– Tighten the fixing screws of the synchronizer body

and 5th gear pinion.
S34-0138
Fitting position of the disc springs for fixing

screws on the 5th gear pinion and synchronizer
body
The outside diameter (concave side -arrows-) points to
the 5th gear.
V34 - 2658

34-9 page 14 S00.5317.00.20
– Before tightening the securing bolts for the synchro-
nizer body and 5th gear pinion -arrows- engage 2
gears ⇒ 34-9 page 6 Fig. N34-0927.
– Fit 5th gear shift fork.
S34-0139
Setting the 5th gear
– Engage 5th gear
– Release screw -1-. Press the sliding sleeve and the
shift fork evenly with a force of approx. 10 N in -the di-
rection of the arrow-.
– Then tighten screw -1- to 25 Nm.
– Remove 5th gear. The sliding sleeve must now be in
Neutral.
• Control measurement:
1
S34-0512
– Press the sliding sleeve -1- evenly with a force of ap-

prox. 10 N towards the 5th gear sliding gear -3-. 1
The sliding sleeve remains in Neutral position.
– With a feeler gauge measure the clearance between a

the sliding sleeve (on the side away from the 5th gear)
and segment -2-.
– The clearance -a- must be determined on both sides
and must not exceed 0.2 mm. The 5th gear synchro- 2 2
nizer ring must travel freely.
S34-0527

S00.5317.00.20
– Mount cover for gearbox housing

– Install both flange shafts with pressure springs, stop
discs and conical rings.
– Installing the guide bushing for clutch release lever
and clutch release bearing ⇒ Chap. 30-2.
V34-2737

34-9 page 16 S00.5317.00.20
34-10 Repairing the gearbox housing and the clutch housing

♦ Drift -MP 3-403-
♦ Auxiliary part -MP 3-403/1-
♦ Pressure plate -MP 3-411-
♦ Threaded rod -MP 3-434-
♦ Pipe section -MP 3-450-
♦ Pressure washer -MP 3-455-
♦ Sealant -AMV 188 200 03-
1 - Gearbox housing
T if replaced: Setting the drive
shaft and differential gear
⇒ Chapter 39-3 1
2 - Oil filler plug, 30 Nm 23
2
T without magnet
3 - Needle bearing 3
T for output shaft
4
T releasing ⇒ Fig. 1 in 34-10 22
page 3 5
T fitting and securing ⇒ Fig. 2 21
in 34-10 page 3
4 - Adjusting washer 6
T for drive shaft 20
T Setting overview ⇒ Chapter 7
39-3 19
8
5 - Outer ring/tapered-roller bear- 10
ing 9
T for drive shaft 18
10
⇒ Chapter 35-1 17
T if replaced: Setting drive
shaft ⇒ Chapter 35-2
6 - Outer ring/tapered-roller bear-
ing
11
T for output shaft 12
⇒ Chapter 35-3 16 13
T if replaced: Setting output 15 14
shaft ⇒ Chapter 35-4
7 - Adjusting washer S34-0508
T for output shaft
T Setting overview ⇒ Chapter 39-3
8 - Outer ring/tapered-roller bearing
T for drive shaft
T removing and installing ⇒ Chapter 35-1
T if replaced: Setting drive shaft ⇒ Chapter 35-2.
9 - Needle bushing
10 - Fitting sleeve
T 2 pieces
Edition 02.03 Repairing the gearbox housing and the clutch housing 34-10 page 1
S00.5317.02.20
11 - Clutch housing
T if replaced: Setting overview ⇒ Chapter 39-3
12 - Ball stud, 25 Nm
T Grease with MoS2-grease
13 - Guide bushing with O-ring
T O-ring is fitted to guide bushing. Replace guide bushing if damaged
T with gasket ring for drive shaft
T Driving out gasket ring ⇒ Fig. 3 in 34-10 page 3
T Driving in gasket ring ⇒ Fig. 4 in 34-10 page 4
T to replace gasket ring remove guide bushing
14 - 18 Nm
15 - Gasket
T for right flange shaft
T replacing ⇒ Chapter 39-1
16 - Bushing
T for right gasket ring ⇒ item 15 in 34-10 page 2
T removing ⇒ Fig. 5 in 34-10 page 4
T installing ⇒ Fig. 6 in 34-10 page 4
17 - Drive for speedometer, 10 Nm
T only for vehicles without ABS
18 - Oil drain plug, 30 Nm
T without magnet
T for differential
T if replaced: Setting the differential gear ⇒ Chapter 39-4.
20 - Magnet
T is held in position by the separator surface of the housing
T for differential
T if replaced: Setting the differential gear ⇒ Chapter 39-4.
22 - Adjusting washer
T for differential
T Setting overview ⇒ Chapter 39-3
23 - Gasket
T for left flange shaft
T replacing ⇒ Chapter 39-1
Repairing the gearbox housing and the clutch housing Edition 02.03
34-10 page 2 S00.5317.02.20
Fig. 1: Driving out needle bearing
MP 3-403
MP 3-455
S34-0140
Fig. 2: Drive in needle bearing up to stop
– Using a drift secure needle bearing in three points in

the gearbox housing with 120° offset.
MP 3-403
MP 3-460
S34-0141
Fig. 3: Driving out the guide bushing
MP 3-403
MP 3-450
S34-0142
Edition 02.03 Repairing the gearbox housing and the clutch housing 34-10 page 3
S00.5317.02.20
Fig. 4: Driving the gasket ring into the guide bush-

ing up to the stop.
MP 3-403
MP 3-403/1
MP 3-411
S34-0143
Fig. 5: Levering out the bushing with a screwdriver
S34-0513
Fig. 6: Inserting the bushing

A - Screw threaded rod from assembly device A
-MP 3-434- into the threaded part of the differential
MP 3-420 B
B - Nut M12 with washer
– By turning the nut -B- insert the bushing over the pres-
sure plate -MP 3-420- up to the stop.
C
Note
If the gearbox is disassembled press the bushing with
pressure plate -MP 3-420- up to the stop.
S34-0514
Repairing the gearbox housing and the clutch housing Edition 02.03
34-10 page 4 S00.5317.02.20
34-11 Disassembling and as-

sembling the gearshift
mechanism on the gear-
box side
♦ Thrust piece -MP 3-448-
♦ Guide piece -MP 3-454-
♦ Interior extractor -Kukko 21/3-
♦ Grease -MoS-2
1 - Gearshift shaft
T pay attention to correct as- 6 7 8 9 10 11
signment ⇒ Spare Part Cat-
alogue
2 - Stop ring
3 - Ball sleeve
T removing ⇒ Fig. 1 in 34-11
page 2
T installing ⇒ Fig. 2 in 34-11
page 2
4 - Shift cover
T with stop for gearshift shaft 5
T 12
5 - Switch for reversing lights, 20
Nm
T Apply thin coat of 7
MoS2grease to peg
4
6 - Relay lever 3 13
7 - Bearing bush
2
8 - Gasket ring
T release with a screwdriver
page 2 14
T Fill space between sealing
lips with sealing grease
-G 052 128 A1-.
9 - Cap
T for gearbox bleeder
10 - 20 Nm 1
S34-0605
11 - Gearshift lever
T insert in such a way that the
interrupted tooth-pitch is opposite the gearshift shaft
T may be replaced with the gearshift mechanism mounted
12 - Circlip
13 - 15 Nm
T secures the gearshift shaft
Edition 11.00 Disassembling and assembling the gearshift mechanism on the 34-11 page 1
S00.5317.01.20 gearbox side
14 - Cap
Fig. 1: Remove the ball sleeve from the cover

MP 3-454
– Before pulling out the ball sleeve destroy the plastic
cage and remove the balls.
MP 3-406
A - Interior extractor 18.5 through 23.5 mm (e.g.
-Kukko 21/3-)
A
S34-0318
Fig. 2: Press the ball sleeve flush into the gearshift

cover
MP 3-448
MP 3-456
MP 3-406
S34-0319
Fig. 3: Press in the gasket up to the stop.
MP 3-479
S34-0320
Disassembling and assembling the gearshift mechanism on the Edition 11.00

34-11 page 2 gearbox side S00.5317.01.20
34-12 Disassembling and assembling the gearshift forks

♦ Driver -MP 1-304-
♦ Distance sleeve -MP 3-458-
♦ Pressure lever -MP 8-506-
1 - Circlip 1 2 1 3 4 1 5 6 7 8 1
page 2
page 2
T always replace
2 - Shift segment
T Identification ⇒ Fig. 3 in
9
34-12 page 2
T It must still be possible to ro- 18 19 20
tate the shift segment freely
once the circlip has been fit- 17
ted
3 - 5th gear shift fork
T setting ⇒ Chap. 34-9
6
4 - 1st/2nd gear shift rail 10
5 - Rev. gear shift rail
9
6 - Washer
7 - Circlip
7 1
8 - Shift segment 9
T Identification ⇒ Fig. 3 in
34-12 page 2 6
T It must still be possible to ro-
tate the shift segment freely
once the circlip has been fit-
ted
16
9 - Angular ball bearing
page 3 15
T installing ⇒ Fig. 5 in 34-12 13 7 1 9 12 11
page 3
14 S34-0510
10 - 3rd/4th gear shift fork
T with shift segment ⇒ Fig. 6 in 34-12 page 3
11 - 1st/2nd gear shift fork
T with shift segment ⇒ Fig. 6 in 34-12 page 3
12 - Shift segment
T Identification ⇒ Fig. 3 in 34-12 page 2
T It must still be possible to rotate the shift segment freely once the circlip has been fitted
13 - Support for reverse gear shift fork
14 - Sliding block (mushroom)
15 - Spring
16 - Gearshift fork reverse gear
17 - 25 Nm
Edition 07.00 Disassembling and assembling the gearshift forks 34-12 page 1
S00.5317.00.20
18 - 5th gear shift fork

19 - 5th gear shift rail
20 - 3rd/4th gear shift rail
Fig. 1: Removing the circlip
– Secure the shift fork in a vice fitted with protective jaws

-B-.
– Lift off the circlip -A-in the direction of the arrow.
Fig. 2: Fitting the circlip
– Press the circlip with a socket wrench into the slot of

the shift segment.
A
Note
It must still be possible to rotate the shift segment freely B
once the circlip has been fitted.
A - Socket wrench, wrench size 10 mm
B - Protective jaws
S34-0525
Fig. 3: Shift segment identification dimension -a-

3
1- Shift segments 1st and 2nd = 11.4 mm a
gear
2- Shift segments 3rd and 4th = 7.6 mm a
gear
3- Shift segments 5th gear = 6.0 mm
a
1
2 S34-0526
Disassembling and assembling the gearshift forks Edition 07.00

34-12 page 2 S00.5317.00.20
Fig. 4: Removing the angular ball bearing
Note
Do not bend the shift forks when removing and installing MP 1-304
the angular ball bearings.
MP 3-453
MP 3-407
S34-0460
MP 3-458
Fig. 5: Insert the angular ball bearing up to the
stop.
Fig. 6: Shift fork with fitted shift segments
Dimension -a- (mm)

1st/2nd gear shift fork 88,4 … 89,1
3rd/4th gear shift fork 96,0 … 96,7
Shift segment assignment ⇒ Fig. 3 in 34-12 page 2. a
V34 - 2031
Edition 07.00 Disassembling and assembling the gearshift forks 34-12 page 3
S00.5317.00.20
Disassembling and assembling the gearshift forks Edition 07.00

34-12 page 4 S00.5317.00.20
35 – Wheels, shafts

sembling the drive shaft
♦ Separating device, e.g. -Kukko 17/1-
Note
♦ When installing new pinions observe the technical
data ⇒ Chap. 00-1.
♦ If the position of the tapered-roller bearing is influ-
enced when parts are replaced the drive shaft must be
reset. Comply with setting overview ⇒ Chap. 39-3.
♦ Replace bearings jointly
Edition 07.00 Disassembling and assembling the drive shaft 35-1 page 1
S00.5317.00.20
1 - Clutch housing
2 - Outer ring/tapered-roller bear-
ing
T pressing out ⇒ Fig. 1 in 22
35-1 page 3 21
page 3 9 17
3 - Inner ring/tapered-roller bear- 8 20
ing 19
T pressing off ⇒ Fig. 3 in 35-1 7
page 4 18
6
T pressing on ⇒ Fig. 4 in 35-1 17
page 4 5 16
4 - Drive shaft
T setting ⇒ Chap. 35-2 15
5 - 3rd gearwheel 4 14
T Collar points to the 4th gear 13
page 5 12
2
T pressing on ⇒ Fig. 7 in 35-1
page 5 1
6 - Circlip
T always replace
7 - 4th gearwheel
T pressing off with inner ring/
tapered-roller bearing and 11
bushing ⇒ Fig. 5 in 35-1
page 4
10
T pressing on ⇒ Fig. 8 in 35-1
page 5
T Collar points to the 3rd gear
N35-0016
8 - Inner ring/tapered-roller bear-
ing
T press off with 4th gearwheel and bushing ⇒ Fig. 5 in 35-1 page 4
T pressing on ⇒ Fig. 9 in 35-1 page 6
9 - Thrust washer
T dimensions 29.2 x 49 x 2.5
T pressing out ⇒ Fig. 11 in 35-1 page 6
11 - Adjusting washer
T Determining thickness ⇒ Chap. 35-2
12 - Gearbox housing
13 - Bushing
T for needle bearing
T press off with 4th gearwheel and inner ring/tapered-roller bearing ⇒ Fig. 5 in 35-1 page 4
T insert thrust washer ⇒ item 9 before assembly
T dimensions 29 x 35 x 24.1
14 - Needle bearing
T dimensions 35 x 40 x 23.8
15 - 5th gear sliding gear
T remove together with 5th gear synchronizer body ⇒ Chap. 34-9
16 - 5th gear synchronizer ring
T with integrated arresters ⇒ Chap. 34-9
Disassembling and assembling the drive shaft Edition 07.00

35-1 page 2 S00.5317.00.20
T check for wear ⇒ Chap. 34-9
17 - Spring
18 - Arresters (3 pieces)
19 - 5th gear synchronizer body
20 - 5th gear sliding sleeve
21 - Disc spring
22 - 80 Nm
T holds disc spring in position with sleeve socket on screw head ⇒ Chap. 34-9
Fig. 1: Pressing out outer ring/tapered-roller bear-

ing
MP 3-423
MP 3-455
S35-0095
Fig. 2: Pressing on outer ring/tapered-roller bear-

ing
MP 3-423
MP 3-455
S35-0049
S00.5317.00.20
Fig. 3: Pressing out inner ring/tapered-roller bear-

ing MP 3-408
MP 3-406
A - Separating device, e.g. -Kukko 17/1- MP 3-407
A S35-0153
Fig. 4: Pressing on inner ring/tapered-roller bear-

ing MP 3-408
MP 3-451
MP 3-406
S35-0050
Fig. 5: Pressing off 4th gearwheel with tapered-

roller bearing and bushing
MP 3-423
MP 3-406 MP 3-4013
S35-0151

35-1 page 4 S00.5317.00.20
Fig. 6: Pressing out 3rd gearwheel
MP 3-448
MP 3-455
MP 3-406
S35-0052
Fig. 7: Pressing on 3rd gearwheel
MP 3-423
MP 3-406
S35-0152
Fig. 8: Pressing on 4th gearwheel

Collar points to the 3rd gear MP 3-408
MP 3-411
MP 3-406
S35-0054
S00.5317.00.20
Fig. 9: Pressing on inner ring/tapered-roller bear-

ing
MP 3-408
MP 3-411
MP 3-406
S35-0055
Fig. 10: Pressing on bushing for needle bearing

MP 3-411
MP 3-406
S35-0056
Fig. 11: Pressing out outer ring/tapered-roller bear-

ing
MP 3-423
MP 3-456
S35-0057

35-1 page 6 S00.5317.00.20
Fig. 12: Pressing on outer ring/tapered-roller bear-
ing
– After setting the drive shaft insert with adjusting wash-

er. MP 3-423
MP 3-413
S35-0058
Fig. 13: 5th gear synchronizer ring

1 - Springs for arresters 1
2 - Sliding sleeve with 3 recesses -arrows A- for the ar-
resters -Pos. 4-
3 - Synchronizer body
4 - Arresters 2
Fitting position: The leg -arrow B- points to the sharp A
teeth of the sliding sleeve -Pos. 2-.
1 B B
B
N35 - 0017
Fig. 14: Assembling sliding sleeve/5th gear syn-

chronizer body
C
– Slide the sliding sleeve over the synchronizer body.
C
The sharp teeth -A- of the sliding sleeve and the collar -B-
of the synchronizer body point in the same direction.
The recesses for the arresters in the sliding sleeve and
the synchronizer body must be positioned above one an-
other ⇒ Fig. 13 in 35-1 page 7.
– Insert arresters (Fitting location: ⇒ Fig. 13 in 35-1 A

page 7).
– Mount the springs with 120° offset under the shoulder
-C-.
C B V35-1320
The angled ends of the spring must be located before the
arresters -arrows-.
S00.5317.00.20

35-1 page 8 S00.5317.00.20
35-2 Setting drive shaft

(Determe adjusting washer for drive shaft)

♦ Gauge block plate -MP 3-405/17-
♦ Universal dial gauge holder -MP 3-447-
♦ Gearbox mount -MP 3-501-
The drive shaft must be reset if

♦ Gearbox housing
♦ Clutch housing
♦ Drive shaft
♦ 4th gearwheel
or the MP 3-423
♦ Tapered-roller bearing
have been replaced.

Setting overview: ⇒ Chap. 39-3 MP 3-413
– Pressing in outer ring/tapered-roller bearing up to the
stop ⇒ Chap. 35-1.
– Press outer ring/tapered-roller bearing into the gear-
box housing up to the stop without adjusting washer
with pressure washer -MP 3-413- S35-0058
– Insert drive shaft in the clutch housing and install
gearbox housing. Tighten heaxagon screw to 25 Nm.
– Fit measuring device and dial gauge in the clutch MP 3-501
housing.
– Turn the drive shaft a number of times before measur-
ing to ensure the tapered-roller bearing sets. Set the
dial gauge to „0“ with 1 mm bias.
MP 3-405/17
Note
This procedure must be repeated before each subse-
MP 3-447
quent measurement as the dial gauge does not return to
is initial setting (0) without turning.
– Press drive shaft towards the dial gauge -direction of

arrow-.
S35-0150
– Read of play on dial gauge and note (example: 1,21).
Note
Dial gauge does not return to initial position.
– Determine the adjusting washer thickness from the ta-

ble ⇒ 35-2 page 2 (example: 1,175).
Edition 07.00 Setting drive shaft 35-2 page 1

S00.5317.00.20
– Remove drive shaft and press out outer ring/tapered-

roller bearing from the gearbox housing with thrust
washer -MP 456-.
– Press outer ring/tapered-roller bearing into the gear-
box housing with thrust washer -MP 3-413- and with
adjusting wahser 1.175.
– Fit gearbox housing and tighten hexagon screws to 25
Adjusting washer table
Bearing clearance Adjusting washer

measured value (mm) Thickness (mm) Spare part No.
0,671 … 0,699 0,650 02A 311 140
0,700 … 0,724 0,675 02A 311 140 A
0,725 … 0,749 0,700 02A 311 140 B
0,750 … 0,774 0,725 02A 311 140 C
0,775 … 0,799 0,750 02A 311 140 D
0,800 … 0,824 0,775 02A 311 140 E
0,825 … 0,849 0,800 02A 311 140 F
0,850 … 0,874 0,825 02A 311 140 G
0,875 … 0,899 0,850 02A 311 140 H
0,900 … 0,924 0,875 02A 311 140 J
0,925 … 0,949 0,900 02A 311 140 K
0,950 … 0,974 0,925 02A 311 140 L
0,975 … 0,999 0,950 02A 311 140 M
1,000 … 1,024 0,975 02A 311 140 N
1,025 … 1,049 1,000 02A 311 140 P
1,050 … 1,074 1,025 02A 311 140 Q
1,075 … 1,099 1,050 02A 311 140 R
1,100 … 1,124 1,075 02A 311 140 S
1,125 … 1,149 1,100 02A 311 140 T
1,150 … 1,174 1,125 02A 311 140 AA
1,175 … 1,199 1,150 02A 311 140 AB
1,200 … 1,224 1,175 02A 311 140 AC
1,225 … 1,249 1,200 02A 311 140 AD
1,250 … 1,274 1,225 02A 311 140 AE
1,275 … 1,299 1,250 02A 311 140 AF
1,300 … 1,324 1,275 02A 311 140 AG
1,325 … 1,349 1,300 02A 311 140
02A 311 140
1,350 … 1,374 1,325 02A 311 140
02A 311 140 A
1,375 … 1,399 1,350 02A 311 140 A
02A 311 140 A
1,400 … 1,424 1,375 02A 311 140 A
02A 311 140 B
1,425 … 1,449 1,400 02A 311 140 B
02A 311 140 B
1,450 … 1,474 1,425 02A 311 140 B
02A 311 140 C
1,475 … 1,499 1,450 02A 311 140 C
02A 311 140 C
Setting drive shaft Edition 07.00

35-2 page 2 S00.5317.00.20
Bearing clearance Adjusting washer

measured value (mm) Thickness (mm) Spare part No.
1,500 … 1,524 1,475 02A 311 140 C
02A 311 140 D
1,525 … 1,549 1,500 02A 311 140 D
02A 311 140 D
1,550 … 1,574 1,525 02A 311 140 D
02A 311 140 E
1,575 … 1,599 1,550 02A 311 140 E
02A 311 140 E
1,600 … 1,624 1,575 02A 311 140 E
02A 311 140 F
1,625 … 1,649 1,600 02A 311 140 F
02A 311 140 F
1,650 … 1,674 1,625 02A 311 140 F
02A 311 140 G
1,675 … 1,699 1,650 02A 311 140 G
02A 311 140 G
1,700 … 1,724 1,675 02A 311 140 G
02A 311 140 H
1,725 … 1,749 1,700 02A 311 140 H
02A 311 140 H
1,750 … 1,774 1,725 02A 311 140 H
02A 311 140 J
1,775 … 1,791 1,750 02A 311 140 J
02A 311 140 J
Perform control measurement

– Insert measuring device and dial gauge. MP 3-501
– Turn the drive shaft a number of times to ensure the
tapered-roller bearing sets.
– Press drive shaft in the direction of the arrow.
– The bearing clearance must be min. 0.01 … max. 0.09
mm. MP 3-405/17
MP 3-447
S35-0150
Edition 07.00 Setting drive shaft 35-2 page 3

S00.5317.00.20
Setting drive shaft Edition 07.00

35-2 page 4 S00.5317.00.20

sembling the output shaft
♦ Thrust ring -MP 3-452-
♦ Alignment rails -MP 3-457-
♦ Insertion tool -MP 3-466-
♦ Tapered-roller bearing extractor -V.A.G 1582-
♦ Gripper -V.A.G 1582/5-
♦ Two-arm extractor (e.g. -Kukko 20/10-)
♦ Hook, e.g. -Kukko 1-250-
♦ Interior extractor, e.g. -Kukko 21/6-
♦ Countersupport, (e.g. -Kukko 22/2-)
♦ Separating device, e.g. -Kukko 17/2-
Note
♦ When installing new pinions or a new output shaft ob-
serve the technical data ⇒ Chapter 00-1.
♦ Removing and installing output shaft ⇒ Chapter 34-9
♦ Replace both tapered-roller bearings together.
♦ The gearboxes manufactured after 09.00 have a mod-
ified 1st gear synchronisation.
♦ Disassembling and assembling the output shaft ⇒ 5
speed gearbox 02J; Rep. Gr. 35
Edition 02.03 Disassembling and assembling the output shaft 35-3 page 1
S00.5317.02.20
Disassembling and assembling the output shaft Edition 02.03

35-3 page 2 S00.5317.02.20
35-4 Setting output shaft

(Determine adjusting washer for drive shaft)

♦ Bolts M8 and M10 -3114/2-
The drive shaft must be reset if

♦ Drive train
♦ Clutch housing
or the
♦ Tapered-roller bearing
have been replaced.

Setting overview: ⇒ Chap. 39-3
MP 3-405/17
Note MP 3-447
New tapered-roller bearings for the output shaft are low
friction. Correct setting of the bearing preload is only pos-
sible by determining the thickness of the adjusting wash-
er.
– Press in outer ring/tapered-roller bearing small in the

clutch housing with a 0.65 mm thick adjsuting washer 3114/2
up to the stop ⇒ Chap. 35-3.
– Insert output shaft and tighten nuts for bearing support
to 25 Nm. S35-0091
– Insert dial gauge (3 mm measuring range) and set to
„0“ with a 1 mm bias.
– Move the output shaft up and down, read off and write
down the clearance on the dial gauge (example: 0.30
mm)
Determine the adjusting screw

The prescribed bearing preload is reached by adding to
the established measured value (0.30 mm) and to the in-
serted adjusting washer (0.65 mm) a constant compres-
sion value (0.20 mm).
Example:
inserted washer 0.65 mm

+ measured value 0.30 mm
+ compression (constant value) 0.20 mm
Thickness of the adjusting washer 1.15 mm
– Remove output shaft and pull out outer ring/tapered-

roller bearing small ⇒ Chap. 35-3.
The following adjusting washers are available:
Edition 07.00 Setting output shaft 35-4 page 1

S00.5317.00.20
Thickness (mm) Spare part No.

0,65 020 311 391 P
0,70 020 311 391 Q
0,75 020 311 391
0,80 020 311 391 A
0,85 020 311 391 B
0,90 020 311 391 C
0,95 020 311 391 D
1,00 020 311 391 E
1,05 020 311 391 F
1,10 020 311 391 G
1,15 020 311 391 H
1,20 020 311 391 J
1,25 020 311 391 K
1,30 020 311 391L
1,35 020 311 391 M
1,40 020 311 391 N
Different tolerances allow to measure the required thick-

– Press in outer ring/tapered-roller bearing with the de-

termined adjusting washer (1.15 mm in the example)
⇒ Chap. 35-3 and install output shaft.
– Tighten nuts for the bearing support in the clutch
housing to 25 Nm and turn a further 90°.
Setting output shaft Edition 07.00

35-4 page 2 S00.5317.00.20
35-5 Disassembling and assembling the reverse shaft

♦ Centering mandrel -MP 3-463-
♦ Countersupport, e.g. -Kukko 22/1-
1 - Clutch housing
2 - Needle bushing 8
page 2
7
page 2
T always replace after disas-
sembling
3 - Reverse pinion
6
4 - Circlip
sembling 5
5 - Reverse gear sliding gear
T remove circlip before replac- 4
ing
T collar points to reverse gear 3
pinion
6 - Reverse shaft 2
T removing ⇒ Chap. 34-9
7 - Needle bushing
T pressing out ⇒ Fig. 3 in
35-5 page 2 1
page 3
sembling
8 - reverse shaft support
⇒ Chap. 34-9
V35-1317
Edition 07.00 Disassembling and assembling the reverse shaft 35-5 page 1
S00.5317.00.20
35 FA B IA 2000 ³ Gearbox 02R
Fig. 1: Removing needle bushing from clutch

housing
A - Countersupport, e.g. -Kukko 22/1-
B - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
A
Note
B
The needle bushing is damaged when removed and must
be replaced.
V35 - 1152
Fig. 2: Pressing in needle bushing -A- in the clutch

housing
MP 3-448
MP 3-455
MP 3-411
A
S35-0071
Fig. 3: Pressing out needle bushing from the re-

verse shaft support
MP 3-449
MP 3-463
MP 3-406
MP 3-411
S35-0072
Disassembling and assembling the reverse shaft Edition 07.00

35-5 page 2 S00.5317.00.20
Fig. 4: Pressing the needle bushing in the reverse
shaft support
MP 3-423
MP 3-406
MP 3-455
S35-0073
Edition 07.00 Disassembling and assembling the reverse shaft 35-5 page 3
S00.5317.00.20
Disassembling and assembling the reverse shaft Edition 07.00

35-5 page 4 S00.5317.00.20
39 – Final drive/Differential
39-1 Replacing the flange shaft

gasket rings (gearbox fit-
ted)
Replacing flange shaft gasket rings

♦ Ejector -MP 9-501-
♦ Attachment -MP 3-419/37-
♦ Sealing grease G 052 128 A1
Removing
For left gasket ring
– Remove front left wheel and raise vehicle.

– Removing damping case below engine/gearbox
⇒ Chap. 34-7.
– Removing the front left wheelhouse liner ⇒ Body
Work; Rep. Gr. 66.
– Turn steering to full left lock.
– Unscrew the drive shaft from the flange shaft.
– Mark installation position of bolts -1- for left steering
joint, otherwise the steering geometry must be
checked.
– Release screws -1-.
– Unbolt coupling rod -2- from the anti-roll bar -arrow-.
– Turn coupling rod upwards.
– Swivel out the wheel-bearing housing.
For right gasket ring
– Removing damping case below engine/gearbox

⇒ Chap. 34-7.
– Turn steering to full right lock.
– Remove cap for right drive shaft from the engine.
– Unscrew the drive shaft from the flange shaft.
For both gasket rings
– Tie up the drive shaft as far as possible. Avoid dam-

aging the paintwork on the drive shaft during this op-
eration.
– Position the catch pan under the gearbox.
– Remove the flange shaft fixing screw; use a drift to
prevent the shaft from turning along.
Edition 11.00 Replacing the flange shaft gasket rings (gearbox fitted) 39-1 page 1
S00.5317.01.20
– Remove the flange shaft with pressure spring.

– Remove gasket rings for flange shaft with extractor
-MP 9-501- and attachment -MP 3-419/37-.
Do not damage the bushing as this will cause leaks. If
damaged replace bushing ⇒ Chap. 34-10.
Installing
The installation occurs in reverse order, while paying at- MP 9-501
tention to the following.
MP 3-419/37
S39-0201
– Drive the new gasket ring in up to the stop, do not twist

the gasket ring.
– Fill the space between the sealing lips and dust lips
with sealing grease -G 052 128 A1-. MP 3-415
– Check gear oil level, if necessary fill up to lower edge
of filler hole ⇒ Chap. 34-8.
Tightening torques
Drive shaft to flange shaft ⇒ Running Gear; Rep. Gr. 40
Flange shaft to gearbox (conical 25 Nm

screw)
Protective cap drive shaft on engine 35 Nm S39-0021
Coupling rod to anti-roll bar 40 Nm
Wheel bolts to wheel hub 120 Nm
Steering joint to track control arm 1) 20 Nm + 90°
1) Always replace these bolts
Replacing the flange shaft gasket rings (gearbox fitted) Edition 11.00
39-1 page 2 S00.5317.01.20
39-2 Disassembling and assembling the differential

♦ Drive bushing -MP 3-427-
♦ Thrust plate -MP 3-464-
♦ Drift -MP 3-510-
♦ Bushing -MP 3-474-
♦ Countersupport, e.g. -Kukko 22/2-
♦ Sealant -AMV 188 200 03-
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100 °C.
♦ Replace both tapered-roller bearings together.
♦ When replacing the tapered-roller bearing of the differential housing, gearbox housing or clutch housing adjust the
differential ⇒ Chap. 39-4.
♦ Pos. 2 ... 6 only applies for service.
Edition 07.00 Disassembling and assembling the differential 39-2 page 1

S00.5317.00.20
1 - Gearbox housing
17 16
2 - Screw
3 - Differential housing 18
T screw to pinion for final drive 19
4 - Pinion for final drive
T series riveted 20
T screwed ⇒ Fig. 11 in 39-2 21 1
page 7
T heat to 100 °C before fitting 22 2
page 6 29 7
T Fitting position ⇒ Fig. 9 in
39-2 page 6 28 8
T place on differential housing 27 9
⇒ Fig. 10 in 39-2 page 6
T is paired with the output 26 10
shaft, replace together
4
25 11
5 - Shim 5
6 - Nut, 70 Nm 24 12
6
7 - Adjusting washer 23 13
T for differential
T Determine thickness
⇒ Chap. 39-4 22
8 - Outer ring/tapered-roller bear- 21 14
ing
T removing ⇒ Fig. 5 in 39-2 20
page 5
19
page 5 18
9 - Inner ring/tapered-roller bear-
ing
17 16 15 A39-0166
page 4
10 - Differential housing
T with riveted pinion for final drive
T when replacing the final drive pinion bore out the rivet heads ⇒ Fig. 7 in 39-2 page 5
T Secure pinion for final drive ⇒ Fig. 11 in 39-2 page 7
11 - Drive wheel for speedometer
T before pressing on the inner ring place it on the differential gear housing up to the stop
12 - Inner ring/tapered-roller bearing
T removing ⇒ Fig. 3 in 39-2 page 4
T pressing out ⇒ Fig. 1 in 39-2 page 3
14 - Clutch housing
15 - Bushing
T for gasket ring support ⇒ item 16
16 - Gasket ring
T replacing ⇒ Chap. 39-1
17 - 25 Nm
T screw to threaded connector to attach the flange shaft ⇒ item 25 in 39-2 page 3
Disassembling and assembling the differential Edition 07.00

39-2 page 2 S00.5317.00.20
18 - Flange shaft
19 - Pressure spring for flange shaft
T fitted behind flange shafts
20 - Thrust washer
T Fitting position: flange to pressure spring, leg to conical ring
21 - Conical ring
T with slots for thrust washer catch
T Fitting position: Cone towards differential housing
22 - Retaining clip
T holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
23 - Stop disc compound
T Install with gearbox oil
24 - Differential bevel gear large
25 - Threaded part
26 - Differential bevel gear shaft
T drive out with drift -MP 3-510-
27 - Tensioning sleeve
T to secure the differential bevel gear shaft
28 - Differential bevel gear small
29 - Differential bevel gear large
Fig. 1: Pressing outer ring/tapered-roller bearing

from clutch housing MP 3-448
– First remove support bushing for sealing ring/flange
shaft. MP 3-459
S39-0022

S00.5317.00.20
Fig. 2: Press outer ring/tapered-roller bearing into

the clutch housing
MP 3-448
No adjusting washer is fitted at the side of the clutch
housing.
MP 3-464
MP 3-407
S39-0023
Fig. 3: Removing inner ring/tapered-roller bearing
– Before fitting the extractor position pressure plate

-MP 3-467- on the differential housing.
Note V.A.G 1582

Both inner rings/tapered-roller bearings of the differential
housing are removed in the same way.
V.A.G 1582/3
V39-1275
Fig. 4: Press on inner ring/tapered-roller bearing

MP 3-408
Note
The inner rings/tapered-roller bearing for the gearbox MP 3-427
housing and clutch housing are pressed on with the same
pressure tools.
MP 3-406
S39-0024

39-2 page 4 S00.5317.00.20
Fig. 5: Remove outer ring/tapered-roller bearing
from gearbox housing
A - Countersupport, e.g. -Kukko 22/2-
B - Interior extractor 46...58 mm, e.g. -Kukko 21/7- A
B
N39 - 0026
Fig. 6: Press outer ring/tapered-roller bearing into

the gearbox housing
– Position adjusting washer under outside ring. MP 3-464 MP 3-448

– Support the gearbox housing with a bushing -MP
3-474- directly below the bearing support.
MP 3-474
MP 3-468
MP 3-407
S39-0025
Fig. 7: Bore out rivet heads
– Bore out the rivet heads on the sunken side with a 12

mm drill and drive out rivets with a drift.
Note
Clean differential gear before and after drilling, protect ta-
pered-roller bearing from boring swarf.
S39-0067

S00.5317.00.20
Fig. 8: Pressing off pinion/final drive
– Fit thrust plate -MP 3-467- on the differential gear MP 3-448

housing.
MP 3-467
MP 3-406 MP 3-407
S39-0026
Fig. 9: Fitting location of the pinion/final drive
– The circular slot -A- points to the screw-on surface of

the differential gear housing.
A
N39-0556
Fig. 10: Heat pinion/final drive to approx. 100 °C and

install.
– Guide the pinion/final drive suring fitting with screws

-A- from the repair kit.
A
A
S39-0068

39-2 page 6 S00.5317.00.20
Fig. 11: Screw pinion/final drive and differential
housing
Use special screws from the repair kit for gerabox 02R.
N39 - 0053
Fig. 12: Removing and installing the tensioning

sleeve for differential bevel gear shaft
Removing
– Cover inner ring/tapered-roller bearing and drive

wheel for speedometer to avoid any possible damage
and swarf.
– Drive out tensioning sleeve with a chisel, position the
chisel in the circular slot.
– Press out differential bevel gear shaft with a drift
-MP 3-510-.
Installing
– Replace tensioning sleeve and drive into the differen- V39-1649

tial housing up to the stop.
Fig. 13: Install the differential bevel gears
– Install stop disc compound with gearbox oil.

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

tion and secure with new tensioning sleeve.

S00.5317.00.20

39-2 page 8 S00.5317.00.20
39-3 Setting overview

Note
♦ When working on the gearbox it is only necessary to re-set the drive shaft, output shaft or differential gear if parts
were replaced that directly affect the settting of the gearbox.
♦ To avoid unnecessary settings refer to the following table:
Set:
Drive shaft Output shaft Differential
⇒ Chap. 35- ⇒ Chap. 35- ⇒ Chap. 39-4
2 4
Replaced part: Gearbox housing x x
Clutch housing x x x
Drive shaft x
Output shaft (drive train) x
Differential gear housing x
Tapered-roller bearing for drive shaft x
Tapered-roller bearing for output shaft x
Tapered-roller bearing for differential x
gear
4th gearwheel x
Edition 07.00 Setting overview 39-3 page 1

S00.5317.00.20
Setting overview Edition 07.00

39-3 page 2 S00.5317.00.20
39-4 Adjusting the differential

gear
♦ Adjusting device -MP 3-462/4-
♦ Bushing -MP 3-462/7-
The differential gear must be re-set when:

♦ Gearbox housing
♦ Clutch housing
♦ Differential housing
or the
♦ differential gear tapered-roller bearing
have been replaced.

Setting overview ⇒ Chap. 39-3
Note
♦ New tapered-roller bearings for the differential gear
are low friction. Correct setting of the bearing preload
is only possible by determining the thickness of the
adjusting washer.
♦ The inner and outer ring of the tapered-roller bearing
are paired. Do not interchange.
– Pressing the outer ring/tapered-roller bearing with

thrust plate -MP 3-464- in the clutch housing ⇒ Chap.
39-2. MP 3-447
– Pressing the outer ring/tapered-roller bearing with
thrust plate -MP 3-464- without adjusting washer in MP 3-405/17
the gearbox housing ⇒ Chap. 39-2.
– Insert the differential gear in the clutch housing.
– Position the gearbox housing and tighten 5 screws to
torque 25 Nm.
– Press differential gear towards the clutch housing
while simultaneously turning eight times.
– Press differential gear towards the gearbox housing
while simultaneously turning eight times. S39-0162
– Set the dial gauge to 0 with 1 mm preload on „0“.
– Move the differential gear up and down, read off and
write down the clearance on the dial gauge. (Example:
0.70 mm)
Determine the adjusting screw
The prescribed bearing preload is reached by adding to
the established measured value a constant compression
value (0.40 mm).
Edition 07.00 Adjusting the differential gear 39-4 page 1

S00.5317.00.20
Example:
measured value 0.70 mm

+ compression (constant value) 0.40 mm
Thickness of adjusting washer S2 = 1.10 mm
– Removing gearbox housing and outer ring/tapered-

roller bearing form the gearbox housing ⇒ Chap. 39-
2.
– Insert adjusting washer of the determined thickness,
the thickest first.
– Press outer ring in again and screw down the gearbox
housing.
The following adjusting washers are available:
Thickness Spare part No.

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

If the measured washer thickness is greater than the one
listed in the table, 2 washers corresponding to the meas-
ured value may be fitted.
Adjusting the differential gear Edition 07.00

39-4 page 2 S00.5317.00.20

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 08.03 List of Supplements

List of Supplements Edition 08.03

Edition 08.03 Table of Contents I

Table of Contents Edition 08.03

00-1 Identification of the gear-

Identification characters and manufacturing date of

Identification of gearbox 02R -arrow 2-.

Edition 08.03 Identification of the gearbox 00-1 page 1

Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 5 speed 02R

Identification of the gearbox Edition 08.03

00-2 Overview of Power Transmission

Edition 07.00 Overview of Power Transmission 00-2 page 1

Overview of Power Transmission Edition 07.00

00-3 General Repair Informa-

Edition 07.00 General Repair Information 00-3 page 1

♦ Install new taper roller bearings as supplied, and do

General Repair Information Edition 07.00

30-1 Clutch control

Summary of components - Foot controls

Edition 02.03 Clutch control 30-1 page 1

Clutch control Edition 02.03

Edition 02.03 Clutch control 30-1 page 3

– Insert over-centre helper spring in the bearing.

Removing and installing the clutch pedal

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

Clutch control Edition 02.03

Edition 02.03 Clutch control 30-1 page 5

Fig. 1: Lift off the support -A- in -the direction of

Fig. 2: Push the actuator rod/master cylinder in the

Removing and installing the master cyl-

Clutch control Edition 02.03

Unlock the actuating rod/master cylinder from the clutch

– Insert pliers -T10005- in the clutch pedal recesses.

Edition 02.03 Clutch control 30-1 page 7

– Remove clutch pedal switch, if provided ⇒ item 7 in

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

Removing and installing the slave cylin-

– Before disconnecting the battery determine the code

Clutch control Edition 02.03

– Unscrew the screws -5- for the slave cylinder.

– Grease tappet end with MoS2-grease. 1

Bleeding the clutch system

Brake fluid specification ⇒ Running Gear; Rep. Gr. 47.

Edition 02.03 Clutch control 30-1 page 9

– Allow approx. 100 cm3 of brake fluid to flow out until

Clutch control Edition 02.03

30-2 Repair of the clutch control

Edition 07.00 Repair of the clutch control 30-2 page 1

Fig. 1: Remove and install the clutch release lever

– Unhook spring -arrow 1- upwards. 2

– First mount spring -arrow 1- on the clutch release le-

Fig. 2: Removing and installing the clutch release

– Press the catch pegs -arrows- together and remove

Repair of the clutch control Edition 07.00