Manual Skoda Octavia - Gearbox m5 002

Service
Workshop Manual
OCTAVIA
5-Speed Manual Gearbox 002
Service Department. Technical Information

S00.5129.50.20 Edition 04.99
The Service Manual is intended only for use within the koda Organisation;
it is not permitted to pass it onto third persons.
1999 KODA AUTO a. s.
Printed in CR
Service
List of Supplements to
OCTAVIA Workshop Manual
Edition: 09.00
5-Speed Manual Gearbox 002

Replaces List of Supplements - Edition: 04.99
Supplement
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Edition
04.99
09.00
Subject
Article Number
Basic Edition of Workshop Manual

Supplement to Basic Edition
S00.5129.50.20
S00.5129.51.20
Contents next page.
The Service Manual is intended only for use within the

koda Organisation; it is not permitted to pass it onto
third persons.
2000 KODA AUTO a. s.
Printed in CR
S00.5129.51.20
OCTAVIA
00
Contents
Service
Technical Data
Identification of gearbox .............................................................................................................

- Code letters, component assignment, ratios, capacities ..........................................................
00-1
00-2
General repair information .........................................................................................................
00-4
Clutch
Page
Survey of power transmission ...................................................................................................
30
30-1
30-1
30-3
30-4
30-5
30-6
30-8
Servicing clutch ...........................................................................................................................
30-11
Shift Mechanism/Housing
Page
34-1
34-1
34-3
34-6
34-7
34-10
34-12
Disassembling and assembling gearbox ..................................................................................

- I - Removing and installing cover for gearbox housing and 5th gear .......................................
- II - Removing and installing gearbox housing, input shaft, output shaft (drive pinion),
differential and shift rods ..........................................................................................................
- Sequence of removal and installation operations .....................................................................
34-23
34-24
Servicing clutch housing ............................................................................................................
34-37
Gears/Shafts
Page
Disassembling and assembling output shaft (drive pinion) ...................................................
35-5
Final Drive/Differential
Page
Servicing gearbox housing ........................................................................................................
Disassembling and assembling shift rods with shift forks .....................................................
39
30-9
Servicing shift mechanism .........................................................................................................

- Installation position of shift mechanism ....................................................................................
- I - Summary of components of shift relay/operating cables .....................................................
- II - Summary of components of shift housing ...........................................................................
- Removing and installing shift housing ......................................................................................
- III - Summary of components of operating cables/shift lever ...................................................
- Setting shift mechanism ...........................................................................................................
Removing and installing gearbox ..............................................................................................

- Inspecting gear oil ....................................................................................................................
35
00-3
Servicing clutch mechanism ......................................................................................................

- Summary of components of pedal assembly ...........................................................................
- Removing and installing over-centre spring .............................................................................
- Removing and installing clutch pedal .......................................................................................
- Summary of components of hydraulic system .........................................................................
- Removing and installing master cylinder ..................................................................................
- Bleeding clutch system .............................................................................................................
Servicing clutch release mechanism ........................................................................................
34
Page
Disassembling and assembling input shaft .............................................................................
34-14
34-22
34-25
34-28
34-35
34-44
35-1
Replacing seals for flange shafts (gearbox installed) .............................................................
39-1
Setting differential .......................................................................................................................
39-12
Disassembling and assembling differential .............................................................................
Edition 04.99
S00.5129.50.20
39-5
------------1 ------------
OCTAVIA
00
Technical Data
Identification of gearbox
K Location on gearbox
The manual gearbox 002 is installed as a
5-speed gearbox in combination with the 1.4ltr./44 kW engine in the koda Octavia.
Code letters of gearbox (arrow 1)
Date of construction of gearbox (arrow 2)
K Date of construction of gearbox

a = Production number of gearbox
b = Identification of year of manufacture
Character
Year
Character
1997
2002
1999
2004
Month
Character
Month
February
August
April
June
1996
1998
2000
Year
2001
2003
2005
c = Month of manufacture
Character
L
January
March
May
July
September
November
October
December
d = Gearbox ratio
Character
7
Edition 04.99
S00.5129.50.20
Transmission ratio of final drive

4.235
------------ 00-1 -------------
00
OCTAVIA
Technical Data
Code letters, component assignment, transmission ratios, capacities

Code letters
Manufactured
Assignment:
Transmission ratio:
from
to
Engine
Gear oil change interval

Clutch control
Clutch plate
Drive shaft flange
------------ 00-2 -------------
08.00
1.4-ltr./44 kW
09.00
1.4-ltr./44 kW
72 : 17 = 4.235
72 : 17 = 4.235
2nd gear
45 : 23 = 1.957
45 : 23 = 1.957
1st gear
45 : 13 = 3.462
45 : 13 = 3.462
3rd gear
38 : 28 = 1.357
38 : 28 = 1.357
5th gear
36 : 42 = 0.857
36 : 42 = 0.857
Reverse
Gear oil specification
01.99
FHW
Final drive
4th gear
Capacity
DTQ
Speedo
40 : 38 = 1.053
40 : 38 = 1.053
29 : 13 x 38 : 29 = 2.923
29 : 13 x 38 : 29 = 2.923
2.4 ltr.
2.4 ltr.
16 : 27 = 0.593
16 : 27 = 0.593
Gear oil G50 SAE 75W90

(synthetic oil)
Gear oil G50 SAE 75W90

(synthetic oil)
hydraulic
hydraulic
filled for life

190 mm
90 mm
filled for life

190 mm
90 mm
Edition 09.00
S00.5129.51.20
OCTAVIA
00
Technical Data
Survey of power transmission
Designation
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft/drive pinion
6 - Differential

Ratio
Edition 04.99
S00.5129.50.20

------------ 00-3 -------------
00
OCTAVIA
Technical Data
General repair information

Extreme care and scrupulous cleanliness, as
well as proper tools are essential requirements
for conducting proper and successful repairs to
the gearbox. The general applicable basic rules
of safety naturally also apply to repair work.
A number of general applicable notes for individual repair operations - which are otherwise
listed at various points in the workshop manual
- are summarized here. They apply to this workshop manual.
Gearbox
When installing, ensure the dowel sleeve
between engine and gearbox are correctly
located.
If the gearbox is replaced, pour in gearbox
oil up to the lower edge of the filler hole.
Capacity and specification page 00-2.

Seals, gaskets
Thoroughly clean contact surfaces and apply THREE BOND 1104 sealant.
Apply sealant evenly - not too thick.
Replace O-rings.
Replace radial shaft seals.
Before installing:
K Lightly oil outer diameter and pack space between sealing lips (arrow) with grease.
After installing:
Inspect gear oil level; top up if necessary to lower
edge of filler hole. Specification page 00-2.
------------
-------------
Edition 04.99
S00.5129.50.20
OCTAVIA

00
Technical Data
Replace circlips.
Do not over-tension circlips.
Circlips must be resting in the base of the

slot.
K Replace roll pins.

Installation position: slot lengthwise to power
flow.
Slacken and tighten nuts and bolts for attaching covers and the housings diagonally
across.
Do not twist particularly sensitive parts - for
example clutch pressure plates - and slacken
and tighten in stages diagonally across.
The tightening torques apply to non-oiled
nuts and bolts.
Always replace self-locking nuts and bolts.
Insert all bearings in the gearbox with gear

oil.
Always replace all the tapered roller bearings mounted on a shaft. Use the same
makes 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. Bearings are
matched.
Position needle bearing with the inscribed
side (larger metal thickness) facing the insertion drift.
Edition 04.99
S00.5129.50.20
------------
-------------
00

Technical Data
OCTAVIA
Re-gauge shims at several points with a micrometer. Different tolerances make it possible to exactly gauge the required thickness
of shim.
Inspect for burrs or damage.
Install only shims which are in perfect condition.
Do not mix up. Assign synchronizer rings to

the same gear when re-installing.
Inspect for wear, replace if necessary.
Insert with gear oil.
Clean and heat on a hot plate to approx.

100 C before pressing on.
The temperature can be checked with a temperature measuring instrument (e.g. V.A.G
1558).
------------
-------------
Edition 04.99
S00.5129.50.20
OCTAVIA
30
Clutch
Servicing clutch mechanism

Summary of components of pedal assembly
Special tools, testers and aids required

Poly resin grease G 052 142 A2
Notes:
Summary of components of hydraulic system page 30-5.
Disconnect earth strap of battery.
Edition 04.99
S00.5129.50.20
Before disconnecting the battery, determine

the coding of radio set fitted with anti-theft
coding.
When the battery is re-connected, check the

vehicle equipment:
- Encode radio
- Re-set clock
- Initialise power windows
Inspection and Maintenance
------------

-------------
30
OCTAVIA
Clutch
Coat all bearing and contact surfaces with

poly resin grease G 052 142 A2.
Before carrying out work on the pedal assembly, remove storage compartment on
drivers side:
Body Fitting Work; Repair Group 70; Removing and installing dash panel.
1 - Mount at bulkhead
For master cylinder and bearing
bracket
2 - Gasket
Always replace
4 - Bolt
5 - Accelerator/brake pedal assembly

6 - 25 Nm
Always replace
7 - Connecting plate
8 - 20 Nm
Always replace
9 - Spacer bush
3 - Bearing bracket
------------
-------------
Edition 04.99
S00.5129.50.20

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30
Clutch
Clutch
Removing and installing
page 30-4

page 30-5
3
4

page 30-3
of
Insert into bearing bracket
Always replace
Always replace

page 30-6
Always replace
nd
Assembly clip 3317
Remove storage compartment at bottom left

on driver side:
Body Fitting Work; Repair Group 70; Removing and installing dash panel.
K-
Tension overcentre spring with clutch pedal

and press on assembly clip 3317 from above.
Note:

Edition 04.99
S00.5129.50.20
Move clutch pedal into rest position; at the

same time, take off overcentre spring together with assembly clip 3317.
Move clutch pedal into rest position.
K-
First of all, position overcentre spring in

mount -B- then depress clutch pedal fully until
the locating stud of the clutch pedal -A- is
positioned against overcentre spring.
Tension overcentre spring with the clutch

pedal and take off assembly clip 3317.
------------
-------------
30

OCTAVIA
Clutch
clutch
Remove overcentre spring page 30-3.
Separate clutch pedal from master cylinder

page 30-6 and press operating rod as far
as the stop toward engine compartment.
K-
Unscrew hexagon nut -A- and pull hexagon

bolt out of the bearing bracket.
Remove clutch pedal.
Installation is carried out in the reverse order.

Pay attention to the following points:
------------
-------------
K-
The mount -A- must be located on the operating rod -B- of the master cylinder.
To lock the mount in place, press clutch pedal

toward bulkhead (direction of arrow); ensure
it is correctly locked.
Edition 04.99
S00.5129.50.20

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30
Clutch
c
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Removing
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Clutch
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Removing page
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Bleeding
page 30-8
Removing page
Edition 04.99
S00.5129.50.20
------------
-------------
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OCTAVIA
Clutch
in
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Release tool 3309

Pliers 10-208 A
Note:
Unbolt master cylinder by working from the passenger compartment.
K-
------------
-------------
Detach feed hose -A- to the brake fluid reservoir and seal.
Pull out locking clip -B- at master cylinder.
Pull out pipe -C- at master cylinder and seal.
Edition 04.99
S00.5129.50.20
OCTAVIA

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Clutch
-
Remove
Re-
Note:
To remove the master cylinder, take out the complete clutch pedal assembly. Before removing,
however, the master cylinder must be separated
from the clutch pedal.
K-
C-
U
move
Remove
2-
Edition 04.99
S00.5129.50.20
------------
-------------
30

OCTAVIA
Clutch
Installation is carried out in the reverse order.

Pay attention to the following points:
K-
The mount -A- must be positioned on the

operating rod -B- of the master cylinder.
To engage the mount in place, press clutch

pedal toward bulkhead (direction of arrow);
ensure it is correctly locked for this step.
After installing the master cylinder, bleed

clutch system page 30-8.
clutch
Brake filling and bleeding appliance

ROMESS S15
Bleeder hose 670 mm
------------
-------------
Use the ROMESS S15 brake filling and

bleeding appliance and bleed the clutch system.
Use a 670 mm bleeder hose for bleeding the

system.
Fit the bleeder hose onto the connection of

the bottle of the brake bleeding appliance.
K-
Fit on bleeder hose at slave cylinder -arrowand open bleeder valve.
After completing the bleeding operation, depress the clutch pedal several times.
Edition 04.99
S00.5129.50.20

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OCTAVIA
30
Clutch
Servicing clutch
Apply THREE BOND 1324 sealant

before installing
3 Clutch
lever
When replacing, release bearing must
also be replaced (lugs on release
bearing do not operate after bearing
is removed from clutch release lever)
Removing and installing page
30-10; remove and install clutch release lever together with release bearing and guide sleeve
Attach to clutch release lever

30-10; remove and install clutch release lever together with release bearing and guide sleeve
Coat contact surface of release bearing with MoS2 grease
Replacing page 34-39, item 18
Grease with MoS2 grease

If clutch housing is replaced, knock in
as far as the stop using extraction tool
for valve stem seal MP 1-174
Tool for removing valve stem seal MP 1-174

MoS2 grease
THREE BOND 1324 sealant

Note:
Remove and install release bearing -1- together

with clutch release lever -3- and guide sleeve
for release bearing -5- in order to avoid damaging the lugs on the release bearing.
Do not wash out bearing, only wipe

off
Replace loud bearings
Grease contact points at release lever with MoS2 grease
30-10; remove and install clutch release lever with release bearing and
guide sleeve
Edition 04.99
S00.5129.50.20
cylinder
30-5
Grease end of tappet with MoS 2
grease
------------
-------------
30

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Clutch
clutch
K-
K-
K-
------------
-------------
Edition 04.99
S00.5129.50.20

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OCTAVIA
30
Clutch
Servicing clutch
Ensure tightly fitted on centering pins

Contact surface for clutch lining free
of grooves, oil and grease
Removing and installing:
1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 13; Disassembling and
assembling cylinder block, crankshaft and
flywheel
Diameter page 00-2

Pay attention to installation position,
spring cage points toward pressure
plate
Centering Fig. 1
Apply thin film of grease to splines
Note:
testers and aids
Grease G 000 100
Clean splines of input shaft and also, if clutch

plates are used, splines of hub, remove corrosion and apply only a very thin film of grease
G 000 100 to the splines of the input shaft. After
this, move clutch plate back and forward on the
input shaft until the hub moves freely on the
shaft. It is essential to remove excess grease.
3
Counterholder MP 1-504
Centering drift MP 2-501
(Gearbox removed)
Notes:
Replace clutch plates and pressure plates if

riveted connection is damaged or loose.
Assign clutch plate and pressure plate by
referring to Parts List and engine code.
Edition 04.99
S00.5129.50.20
Removing and installing Fig. 1

Inspecting ends of diaphragm spring
Fig. 3
Note:
Pressure plates are protected against corrosion

and grease. They must only be cleaned at the
contact surface otherwise the life of the clutch
will be considerably reduced.
4
Slacken and tighten in stages diagonally across

------------
-------------
30

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OCTAVIA
Clutch
clutch
Note:
Contact surface of pressure plate and lining of

clutch plate must be making contact with flywheel over complete surface. Only then, insert
securing bolts. On no account pull on pressure
plate. Otherwise centering holes of pressure
plate and centering pins of flywheel will be damaged.
in
in
K i .3
l
------------
-------------
Edition 04.99
S00.5129.50.20
OCTAVIA
Servicing shift mechanism

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34
Installation position of shift mechanism

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

C - Heat shield
T
1 - Gearbox shift lever
2 - Shift relay mechanism
Notes:
Disconnect earth strap from the battery when

working on the shift mechanism in the engine compartment.

the coding of radio sets with anti-theft code.
When the battery is re-connected, check the
vehicle equipment:
- Encode radio
- Re-set clock
Take out shift mechanism in order to replace

the operating cables page 34-7.
Do not kink operating cables.

T
Edition 04.99
S00.5129.50.20
------------
-------------
34
I - Assembly overview - shift relay mechanism, shift mechanism cables

page 34-3
II - Assembly overview - shift housing
page 34-6
OCTAVIA
Removing and installing shift housing page

34-7.
Setting shift mechanism page 34-12.
III - Assembly overview - shift mechanism

cables, shift lever page 34-10
------------ 34-2 -------------
Edition 09.00
S00.5129.51.20
OCTAVIA
34
I - Assembly overview - shift relay mechanism, shift mechanism cables
Note:
Grease bearing points and contact surfaces with
1 - Shift cable
Fitting location page 34-1
2 - Selector cable
Fitting location page 34-1
3 - Circlip
Do not damage boot when removing
Edition 09.00
S00.5129.51.20
4 - Spring
Models 03.99
5 - 25 Nm
6 - 20 Nm
7 - Support
8 - 25 Nm
2 in total
9 - Supporting angle bracket
------------ 34-3 -------------
34
OCTAVIA
10 - PAS gear
With heat shield
14 - 25 Nm
Tighten after setting shift mechanism
11 - Boot
15 - Gearbox
12 - Gearbox shift lever

Grease guide for ball stud/shift relay
lever (item 42) with poly resin grease
G052142A2
After installing, set shift mechanism
page 34-12
16 - Ball stud
13 - 20 Nm
Before installing, apply Loctite 648
locking fluid
------------ 34-4 -------------
17 - Seal
18 - Selector rod
Grease ball sockets with poly resin
grease G 052 142 A2 before installing
Edition 09.00
S00.5129.51.20

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OCTAVIA
33 - oot
Carefully pull over shift cable and end
piece
9-
- Seal
angle
3-
- Seal
- Mounting
3 -
3 -
3 39 -
30 -
34 -
3 -
4-
9-
34
40 -
4 -
For attaching mounting bracket to

transmission
4 -

transmission
44 -

transmission
4 -
43 -
4 - Shield
3 - oot
Carefully pull over selector cable and
end piece
Edition 09.00
S00.5129.51.20
------------ 34-5 -------------

OCTAVIA

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-item 2-
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When removing also take off gearshift
knob -item 1 Separating cover from gearshift knob
page 34-9
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Connects cover to gearshift knob
Removing page 34-9
------------
-------------
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34
Shift housing
page
elded to
and
onto
and
ing
-
Remove
shift
page
K-
ake
and
K-
Edition 04.99
S00.5129.50.20
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K-
K-
------------
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OCTAVIA
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Notes:
Replace
1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 26; Removing and installing parts of exhaust system
ightening
K-
Edition 04.99
S00.5129.50.20
Shift housing to body

M8 bolt
25 Nm
Shift housing to body

M8 nut
25 Nm
Cross member to body
25 Nm
Bolt of shift cable to shift intermediate lever
25 Nm
Turn the cover inside out.
Use a screwdriver to lever off connection part

-arrow-.
Pull connection part off gearshift knob.
Turn gearshift knob to the outside and pull it

off the cover.
Turn cover inside out.
Insert gearshift knob into cover.
Push connection part over gearshift knob and

cover and compress until it locks in place.
------------
-------------
34

- shift mechanism
OCTAVIA
shift

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Grease bearing points and contact surfaces with

-
To selector angle bracket
Always replace
3------------
-------------
4 - Shift
To shift lever
-
7-
8-
Always replace
Edition 09.00
S00.5129.51.20

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OCTAVIA
9
Heat cap before fitting on (for example in hot water)
housing
Insert into bearing plate after assembling complete shift lever
34

For models 08.99
For models 08.99
For models 08.99
Shift lever and shift lever guide are

assembled to form single component
Insert into bush item 10
Fits only in one position
Shift lever and shift lever guide are

assembled to form single component
For models 08.99
Clip onto shift lever

Fitting location: the lug -arrow- points
toward shift lever mounting
Pull shift lever in direction -arrow A- and at

the same time use a screwdriver to push the
spacer sleeve down fully in direction -arrow
B- and remove the circlip.
Note:
Do not twist spacer sleeve when pushing down

with screwdriver. Carefully relieve pressure on
mounting slot in shift lever for circlip.
Edition 09.00
S00.5129.51.20
------------
-------------

OCTAVIA

Shift lever gauge 3422

Sliding block T30006
K-
The shift lever gauge is composed of the

bottom part of the gauge 3422 and the sliding block T30006.
Replace sliding block of shift lever gauge

3422 with sliding block T30006 after slackening the screw (arrow).
Notes:
Requirements for correct setting of the shift

mechanism are as follows:
Operating and transmission elements of shift

mechanism in proper condition.
Insulating pieces for mounting shift and selector cables in proper order at all operating
elements (not worn).
Shift cable and selector cable operate freely.
In addition, the gearbox, clutch and clutch

mechanism must be in proper condition.
Gearbox in Neutral position.
------------
-------------
Detach gearshift knob together with cover

page 34-7.
K-
Slacken bolt of shift cable of shift intermediate lever -arrow A-.
K-
Slacken nut of selector rod of gearbox shift

lever -arrow B-.
Shift cable and selector rod must now move

freely in the slots.

S00.5129.50.20
OCTAVIA

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Edition 04.99
S00.5129.50.20
------------
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Gearbox mount 3282
Adjusting plate T30007

Adapter MP 3-419/40
Transporting device MP 3-478

Assembly device MP 5-402
Supporting device MP 9-200

Grease G 000 100
Loctite 648
Remove engine trim panel.
Seal oil filler neck.

the coding of radio sets fitted with anti-theft
code.
Disconnect earth strap of battery.
K-
------------
-------------
Detach intake hose -1- from lock carrier.
Detach air hose -2- from warm air baffle of

exhaust manifold.
Detach intake hose -3- from intake connection of throttle valve control unit -arrow-.
Remove air filter housing complete by unscrewing bolts -4- and -5-.
Detach earth strap from top bolt connecting

engine and gearbox.

S00.5129.50.20
OCTAVIA

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Note:
Do not depress clutch pedal.
K-
K-
Edition 04.99
S00.5129.50.20
------------
-------------

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K-
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------------
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S00.5129.50.20
OCTAVIA
K-
K-
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Edition 04.99
S00.5129.50.20
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K-
K-
Note:
Pay attention to power steering line when lowering engine/gearbox unit.
K-
------------
-------------

S00.5129.50.20
OCTAVIA

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K-
K-
Edition 04.99
S00.5129.50.20
------------
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Notes:
Clean splines of input shaft and apply a thin

film of grease G 000 100.
When replacing the gearbox, ensure the intermediate plate between engine and gearbox is correctly positioned.
Check whether dowel sleeves are present
in cylinder block for centering engine/gearbox; insert if necessary.
Install starter/cable:
Set shift mechanism page 34-12.
When re-connecting the battery, check the

vehicle equipment:
- Encode radio
- Re-set clock

to

------------
-------------

S00.5129.50.20
OCTAVIA

34
K Supporting bracket and mounting bracket at top

of gearbox
Bolt -A- for mounting bracket and guide
bush (speedo) to gearbox
20 Nm
Bolt -B- and -C-
20 Nm
K Mounting bracket to bottom of gearbox

Bolt -A-
20 Nm
Bolt -B- for attaching shift lever -C- to shift

shaft 1)
1)
20 Nm
Apply Loctite 648 locking fluid before installing.
ightening
Supporting angle bracket - gearbox

PAS M8
25 Nm
Pendulum support - gearbox1) M10
40 Nm + 90
Cover for gearbox housing - gearbox

mount1) M12
80 Nm
Pendulum support - subframe1) M8
Drive shaft - flange shaft1) (tighten

diagonally across in 2 stages) M8
Running Gear, Repair Group 40
20 Nm + 90
Steering joint - track control arm 1) M8

Coupling rod - track control arm
20 Nm + 90
Starter - gearbox M8
25 Nm
Wheel bolts - wheel hub
120 Nm
Nut for attaching double

clamp/exhaust system
1)
Edition 09.00
S00.5129.51.20
45 Nm
40 Nm
Always replace these bolts.
------------
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l Vehicle standing on level ground
Specification of gearbox oil page 00-2

-
K-
Turn steering to full left lock.
Unscrew plug for inspecting gearbox oil (arrow).
The oil is at the correct level if the gearbox is

filled up to the lower edge of the oil filler hole.
-
Screw in plug (arrow) with new seal, 35 Nm.

------------
-------------
Unscrew plug (arrow).
Pour in gearbox oil up to lower edge of filler

hole.
Screw in plug (arrow).
Start engine, engage a gear and allow gearbox to rotate for about 2 minutes.
Switch off engine and unscrew plug (arrow).
Once again pour in gearbox oil up to lower

edge of filler hole.
Screw in plug (arrow) with new seal, 35 Nm.

S00.5129.50.20

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34
and
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Edition 04.99
S00.5129.50.20
shaft
------------
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-
Replace
Removing and installing from page
34-28
34-28


34-28

Notes:
The gearbox must be lowered with the supporting device MP 9-200 in order to be able
to remove and install the cover of the gearbox housing.
If the cover of the gearbox housing is fitted

on with the gearbox installed, top up gear oil
and check oil level page 34-22.

4 total
+

5 in total
+

-------------

Servicing page 34-35
Installation position: oil pockets -arrow- point toward 5th gear synchronizer body

Prevents locking pieces from moving

out
6

Installation position: the higher outer
diameter points toward the cover for
gearbox housing

------------
Installation position page 34-33
-
Replace
For input shaft

Always replace
Pay attention to removal and installation sequence for slackening and tightening the nut from page 34-28
For output shaft

Always replace
Pay attention to removal and installation sequence for slackening and tightening the nut from page 34-28

S00.5129.50.20

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and
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shaft
page
shaft

page
Edition 04.99
S00.5129.50.20
sealant
page
sealant
housing
page
magnet
------------
-------------

OCTAVIA

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Disassembling and assembling
page 35-5


page 34-44
------------
-------------

page 35-1

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S00.5129.50.20

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Insert with reverse idler gear shaft
2 in total
9 C
housing
Servicing page 34-37
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page 39-5
K Fig.
-
of
shaft
in
Use extractor MP 3-508 to knock roll pin -3into reverse idler gear shaft -1- to maintain
dimension -a- = 6 mm.
2 - Reverse idler gear
Edition 04.99
S00.5129.50.20
------------
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Universal tool MP 3-419

Adapter MP 3-419/40
Gearbox holder MP 3-501
Extractor for roll pin MP 3-509

Cross-cut chisel MP 3-533
Special tool for securing nut MP 3-605

Repair stand MP 9-101
Sealant, e.g. THREE BOND 1104

K-
------------
-------------
Drain gear oil.
Attach gearbox to repair stand (arrows).
Remove clutch release lever, release bearing and guide sleeve page 30-9.

S00.5129.50.20
OCTAVIA
K-
K-
K-
Edition 04.99
S00.5129.50.20

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K-
K-
------------
-------------

S00.5129.50.20
OCTAVIA
K-
K-
Edition 04.99
S00.5129.50.20

34
Remove
move
------------
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S00.5129.50.20
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When inserting the locking bolt, ensure that the

sleeve of the shift finger is not at the level of the
hole. If this is the case, raise sleeve of shift finger slightly in order to avoid damage to the
thread.
K-
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Edition 04.99
S00.5129.50.20
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K-
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S00.5129.50.20

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34
Servicing
housing
housing
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race of taper
and
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testers and aids
39-13
MP
Edition 04.99
S00.5129.50.20
sealant
39-1
sealant
------------
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34
Servicing
housing
testers and aids
Gearbox
or r
Edition 04.99
S00.5129.50.20
------------
-------------

OCTAVIA

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before installing


------------

before installing

For reverse gear lever
4 x 25 mm
Use extractor for locking pin 4 mm
MP 3-508 for installing
-------------

S00.5129.50.20

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For output shaft

page 35-7, item 32
Installation position Fig. 2
3
4
30 S
For shift shaft
Can be replaced with gearbox installed
Use screwdriver to lever out
Inserting Fig. 7
For input shaft

page 35-1, item 9
housing
tube
Use pliers for removing
Use drift to knock in as far as stop
33
34
For gearbox breather

Removing Fig. 3
Installing Fig. 4

before installing
Shift shaft
For removing, knock roll pins -item 33and -item 34- down and out
For installing, knock in roll pins from
above
5 x 22 mm
3 x 22 mm

before installing
Magnet
Is held by the contact surface of the
housing
uide gate
S
For right flange shaft
Replacing page 39-1
39
40
bush
Always replace
For speedometer
34
bush
For shift shaft
Removing Fig. 5
Inserting Fig. 6
Edition 04.99
S00.5129.50.20
of t
For differential
Removing and inserting from page
39-5
If replaced: set differential
page 39-12
Setting position of shift lever

Fig. 10
Apply Loctite 648 before installing
43
44
Removing Fig. 11
Inserting Fig. 12
------------
-------------

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Remove
K

------------
-------------

S00.5129.50.20
OCTAVIA

34
seal
input shaft
not as
as
The seal is in its correct installation position once

the guide sleeve has been installed.
shaft
shift
A - Internal extractor 14 ... 19 mm, e.g. Kukko

21/2
shift
Use special tool MP 3-606 as this at the same

time prevents the bearing bush from wandering
out.
Edition 04.99
S00.5129.50.20
------------
-------------

OCTAVIA

Both roll pins -A- and -B- fit into one another.
Both slots must be opposite and be facing longitudinally to the power flow -arrow-.
------------
-------------

Connect wrench for threaded bush T30009

to threaded bush in clutch housing.
Turn out threaded bush.
Connect threaded bush to wrench for

threaded bush T30009.
Coat the outer thread of the threaded bush

with THREE BOND 1305 sealant.
Turn threaded bush into the clutch housing

and tighten to the specified torque.

S00.5129.50.20
OCTAVIA

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34
Notes:

bush
shift
Edition 04.99
S00.5129.50.20
bush
shift
------------
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Extractor for locking pin MP 3-509
)
5 x 22 mm
Use extractor for locking pin
MP 3-509 for removing
------------

5 mm
-------------

S00.5129.50.20
OCTAVIA
35
Gears/Shafts
Disassembling and assembling input shaft
Note:

1 - Nut, 60 Nm
Always replace
Pay attention to removal and installation sequence for slackening and tightening the nut page 34-28
2 - 5th speed gearwheel
34-28
3 - Gearbox housing
4 - Grooved ball bearing
Pressing off Fig. 1
Pressing on Fig. 2
5 - 4th speed gearwheel
Pressing off Fig. 3
Pressing on Fig. 6
Collar points toward 3rd gear
6 - Spacer sleeve
Pressure plate MP 3-406
7 - 3rd speed gearwheel

Pressing off Fig. 4
Pressing on Fig. 5
Collar points toward 4th gear

Thrust piece MP 3-411
Plunger MP 3-448
Tube section MP 3-450
Thrust washer MP 3-4014
8 - Input shaft
9 - Cylinder roller bearing
Removing Fig. 7
Inserting Fig. 8
Installation position: designation on
bearing points up page 34-40,
Fig. 2
Separating device Kukko 17/1
10 - Clutch housing
Separating device Kukko 17/2
11 - Washer
Workshop press, e.g. V.A.G 1290 A
12 - 10 Nm
Edition 04.99
S00.5129.50.20
------------

-------------

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S00.5129.50.20
OCTAVIA

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Gears/Shafts
off 3rd
3rd
4th s
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to
Edition 04.99
S00.5129.50.20
------------
-------------

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Puller MP 3-520
shaft
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Setting tool MP 9-501
Edition 04.99
S00.5129.50.20
------------
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OCTAVIA

Always replace
Pay attention to removal and installation sequence for slackening and tightening the nut page 34-28

Installation position: the higher outer
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when pulling out flange shaft.

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S00.5129.50.20
------------
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39
Final Drive/Differential
OCTAVIA
K-
Clamp flange shaft in a vice using protective

jaws. Press circlip out of groove of flange
shaft with new circlip -A-.
Use plastic-headed hammer to knock in flange shaft.
Bolt left drive shaft or right drive shaft, respectively, to flange shaft.
Further installation is carried out in the reverse order.
Inspect gear oil level; top up to lower edge

of filler hole if necessary page 34-22.
Tightening torques
Component
Drive shaft - flange shaft1) (tighten
diagonally across in 2 stages) M8
Running Gear, Repair Group 40
Steering joint - track control arm 1) M8
20 Nm + 90
Pendulum support - subframe1) M8
20 Nm + 90
Coupling rod - track control arm

Wheel bolts - wheel hub
Nut for attaching double
clamp/exhaust system
1)
------------ 39-4 -------------
Tightening
torque
45 Nm
120 Nm
40 Nm
Always replace these bolts.
Edition 09.00
S00.5129.51.20

OCTAVIA

Counterholder MP 1-223
Two-legged puller Kukko 20/10
Extraction hook Matra V/170
Internal extractor Kukko 21/7
Countersupport Kukko 22/2
Insertion drift MP 3-511

S00.5129.50.20
------------
-------------

OCTAVIA

Notes:
Heat inner race of taper roller bearing to

100 C before installing.
Always replace both taper roller bearings.
If taper roller bearings, differential housing,

gearbox housing and clutch housing are replaced, set differential page 39-12.
For differential
Determining thickness page 39-13
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Inserting Fig. 2
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------------
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S00.5129.50.20

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Inserting Fig. 10
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replace together
For flange shaft

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Pressing on Fig. 8
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.

A - Countersupport, e.g. Kukko 22/2
B - Internal extractor 46...58 mm, e.g. Kukko

21/7

S00.5129.50.20
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End gauge MP 3-405/17
Universal dial gauge holder MP 3-447

Insertion drift MP 3-511
Internal extractor Kukko 21/7

Countersupport Kukko 22/2
Dial gauge
It is necessary to re-set the differential if

gearbox housing
clutch housing
differential housing
or the
taper roller bearings of the differential

are replaced.
Notes:
New taper roller bearings for the differential

have a low friction. For this reason, the friction torque can only be used as a means of
inspection to a limited extent. It is only possible to correctly set the bearing preload by
determining the thickness of the shim.
The inner and outer races of taper roller bearings are matched. Do not mix up.
K-
Use tube section MP 3-450 to support clutch

housing directly below bearing mount.
Use insertion drift MP 3-511 to press outer

race of taper roller bearing into clutch housing.
Note:
No shim is fitted on the side of the clutch housing.
------------
-------------

S00.5129.50.20
OCTAVIA

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When carrying out the measurement, do not

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settle and the result of the measurement will be
falsified.

S00.5129.50.20
------------
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S00.5129.50.20

Manual Skoda Octavia - Gearbox m5 002

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Manual Skoda Octavia - Gearbox m5 002

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Service

Service Department. Technical Information

5-Speed Manual Gearbox 002

Basic Edition of Workshop Manual

Contents next page.

The Service Manual is intended only for use within the

Identification of gearbox .............................................................................................................

General repair information .........................................................................................................

Survey of power transmission ...................................................................................................

Servicing clutch ...........................................................................................................................

Disassembling and assembling gearbox ..................................................................................

Servicing clutch housing ............................................................................................................

Disassembling and assembling output shaft (drive pinion) ...................................................

Servicing gearbox housing ........................................................................................................

Disassembling and assembling shift rods with shift forks .....................................................

Servicing shift mechanism .........................................................................................................

Removing and installing gearbox ..............................................................................................

Servicing clutch mechanism ......................................................................................................

Servicing clutch release mechanism ........................................................................................

Disassembling and assembling input shaft .............................................................................

Replacing seals for flange shafts (gearbox installed) .............................................................

Setting differential .......................................................................................................................

Disassembling and assembling differential .............................................................................

K Date of construction of gearbox

Transmission ratio of final drive

------------ 00-1 -------------

Code letters, component assignment, transmission ratios, capacities

Gear oil change interval

Drive shaft flange

------------ 00-2 -------------

Gear oil specification

Gear oil G50 SAE 75W90

Gear oil G50 SAE 75W90

filled for life

filled for life

Survey of power transmission

------------ 00-3 -------------

General repair information

Capacity and specification page 00-2.

Do not over-tension circlips.

Circlips must be resting in the base of the

K Replace roll pins.

Insert all bearings in the gearbox with gear

Install only shims which are in perfect condition.

Do not mix up. Assign synchronizer rings to

Clean and heat on a hot plate to approx.

Servicing clutch mechanism

Special tools, testers and aids required

Disconnect earth strap of battery.

Before disconnecting the battery, determine

When the battery is re-connected, check the

Coat all bearing and contact surfaces with

5 - Accelerator/brake pedal assembly

Removing and installing

Removing and installing

Removing and installing

Assembly clip 3317

Remove storage compartment at bottom left

Tension overcentre spring with clutch pedal

Move clutch pedal into rest position; at the

Move clutch pedal into rest position.

First of all, position overcentre spring in

Tension overcentre spring with the clutch