Gearbox 02Q

Service
Workshop Manual
OCTAVIA II 2004 ➤
Gearbox 02Q
Edition 02.04
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Control, housing
35 - Wheels, shafts
39 - Final drive, differential gear
OCTAVIA II 2004 ➤
Gearbox 02Q - Edition 02.04
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification of rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 4
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Front-wheel-drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2 Summary of components - Foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Removing and installing the over-centre helper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Removing and installing the clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5 Removing and installing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.6 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.8 Summary of components - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9 Test of hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.10 Bleed the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2 Remove and install slave cylinder with clutch release bearing . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Replace gasket ring for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Summary of components - Repairing the clutch make “Sachs” . . . . . . . . . . . . . . . . . . . . 42
3.2 Removing and installing clutch make “Sachs” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Summary of components - Repairing the clutch make “LuK” . . . . . . . . . . . . . . . . . . . . . . 46
3.4 Removing and installing clutch make “LuK” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 49
34 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Summary of components - gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Remove and install gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Summary of components - Gearshift mechanism (up to 10.06) . . . . . . . . . . . . . . . . . . . . 58
1.6 Summary of components - Gearshift mechanism (as of 11.06) . . . . . . . . . . . . . . . . . . . . . . 60
1.7 Disassembling and assembling the gearshift mechanism (as of 11.06) . . . . . . . . . . . . . . 62
1.8 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.9 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.10 Removing and installing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.11 Removing and installing shift cable and selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.12 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Removing gearbox - Front-wheel-drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Removing gearbox - Four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents i
OCTAVIA II 2004 ➤
2.3 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.4 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Inspect gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Removing and installing angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Remove angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 Install angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5 Inspecting gear oil in the angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1 Inspecting oil level in the angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.2 Top up oil in angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.3 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 117
6.4 Removing and installing the drive shaft, output shafts, differential gear, gearshift rods and
angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5 Mounting sequence up to production date 20 01 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.6 Mounting sequence as of production date 21 01 8 (gearbox “with” circlip A for the cap/drive
shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.1 Summary of components - Gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.2 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8.1 Summary of components - Front-wheel-drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8.2 Summary of components - Four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.3 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9 Repairing gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.1 Disassembling and assembling gearshift forks up to 05.09 . . . . . . . . . . . . . . . . . . . . . . . . 161
10.2 Disassembling and assembling the gearshift forks as of 06.09 . . . . . . . . . . . . . . . . . . . . . . 164
35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Modifications in the area of the grooved ball bearing/drive shaft . . . . . . . . . . . . . . . . . . . . 169
2 Output shaft gears 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.1 Disassembling and assembling output shaft gears 1 through 4 . . . . . . . . . . . . . . . . . . . . . . 171
2.2 Synchronization for 1st through 3rd gear is modified on certain gearboxes . . . . . . . . . . . . 180
2.3 Setting output shaft gears 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3 Output shaft 5th/6th gear/reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.1 Disassembling and assembling output shaft 5th/6th and reverse gear . . . . . . . . . . . . . . . . 187
3.2 Setting output shaft 5th/6th and reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
39 - Final drive, differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1 Replacing gasket rings for flange shaft or rigid shaft with gearbox installed . . . . . . . . . . . . 197
1.1 Replacing the left flange shaft gasket ring (front-wheel drive and four-wheel drive) . . . . . . 197
1.2 Replacing the right rigid shaft gasket ring (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . 198
1.3 Replacing the right flange shaft gasket ring (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . 199
1.4 Replacing the right flange shaft gasket ring (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . 200
1.5 Replacing gasket rings between angle gearbox and manual gearbox (four-wheel drive) . . 202
1.6 Replacing the needle bearing (polygon bearing) and gasket ring on right flange shaft (four-
wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.7 Replacing the angle gearbox output flange gasket ring (four-wheel drive) . . . . . . . . . . . . 207
2 Setting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
ii Contents
OCTAVIA II 2004 ➤
3.1 Summary of components - Front-wheel-drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

3.2 Summary of components - Four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.3 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.4 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.1 Removing and installing “two-piece” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.2 Removing and installing “one-piece” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5 Repairing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.1 Repairing “two-piece” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.2 Repairing “one-piece” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
6 Removing and installing the rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6.1 Summary of components - Removing and installing the rear final drive “02D/0AV” . . . . . . 240
6.2 Summary of components - Removing and installing the rear final drive “0BR” . . . . . . . . . . 242
6.3 Removing and installing the rear final drive “02D/0AV” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6.4 Removing and installing the rear final drive “0BR” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6.5 Replace rubber-metal bearing at the rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
7 Replace gasket rings for flange shaft rear final drive (rear final drive installed) . . . . . . . . . . 258
7.1 Removing and installing gasket ring for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
8 Replace gasket ring for flange on the Haldex coupling on installed rear final drive . . . . . . 260
8.1 Remove and install gasket ring for flange on the Haldex coupling . . . . . . . . . . . . . . . . . . . . 260
9 Electrical/electronic components and fitting locations for the Haldex coupling . . . . . . . . . . 266
9.1 Electric/electronic components and their fitting locations (final drive “02D/0AV”) . . . . . . . . 266
9.2 Electrical/electronic components and their fitting locations (final drive “0BR”) . . . . . . . . . . 268
9.3 Summary of components - Four-wheel drive control unit J492 (final drive “02D/0AV”) . . . . 270
9.4 Summary of components - Four-wheel drive control unit J492 (final drive “0BR”) . . . . . . . . 271
9.5 Removing and installing the four-wheel drive control unit J492 (final drive “02D/0AV”) . . . . 272
9.6 Removing and installing the four-wheel drive control unit J492 (final drive “0BR”) . . . . . . 275
9.7 Removing and installing the pump for Haldex coupling (final drive “02D/0AV”) . . . . . . . . . . 277
9.8 Removing and installing the pump for Haldex coupling (final drive “0BR”) . . . . . . . . . . . . 279
10 Removing and installing Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
10.1 Summary of components - Haldex coupling (final drive “02D/0AV”) . . . . . . . . . . . . . . . . . . 282
10.2 Summary of components - Haldex coupling (final drive “0BR”) . . . . . . . . . . . . . . . . . . . . . . 283
10.3 Removing and installing Haldex coupling (final drive installed) . . . . . . . . . . . . . . . . . . . . . . 283
11 Disassembling and assembling Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
11.1 Summary of components - Disassembling and assembling “Haldex coupling of the 2nd
generation” (final drive “02D/0AV”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
11.2 Summary of components - Disassembling and assembling “Haldex coupling of the 4th
generation” (final drive “0BR”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
11.3 Replacing grooved ball bearing for Haldex coupling (final drive “02D/0AV”) . . . . . . . . . . . . 292
11.4 Removing and installing the oil filter for Haldex coupling (final drive “02D/0AV”) . . . . . . . . 298
12 Check oil level in the Haldex coupling or change oil or top up with oil . . . . . . . . . . . . . . . . 300
12.1 Check oil level in the Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
12.2 Changing oil in the Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
12.3 Refilling oil in Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
13 Checking the gear oil level in the rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
13.1 Checking the gear oil level in the “rear final drive 02D/0AV” . . . . . . . . . . . . . . . . . . . . . . . . 306
13.2 Checking the gear oil level in the “rear final drive 0BR” . . . . . . . . . . . . . . . . . . . . . . . . . . 307
14 Inspect operation of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
14.1 “Final drive 02D/0AV” - Functional test for opened Haldex coupling on vehicles fitted with
manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
14.2 “Final drive 02D/0AV” - Functional test for closed Haldex coupling on vehicles fitted with
manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
14.3 “Final drive 0BR” - Functional test of Haldex coupling with manual gearbox . . . . . . . . . . . . 309
Contents iii
OCTAVIA II 2004 ➤
iv Contents
OCTAVIA II 2004 ➤
00 – Technical data
1 Identification of the gearbox
Assignment ⇒ page 4 .
1.1 Location on the gearbox

Front-wheel-drive
Identification characters and production date -arrow 1-
Identification of gearbox 02Q -arrow 2-.
Four-wheel drive
Identification characters and production date -arrow 1-
Identification of gearbox 02Q -arrow 2-.
Gearbox 02Q -arrow 2-
1. Identification of the gearbox 1

OCTAVIA II 2004 ➤
Identification characters and production date of the gearbox

-arrow-
Example: GRF 25 11 3
I I I I
I I I I
Identification Day Month Manufacturing
characters year 2003
Additional data gives information about the manufacturing facto‐
ry.
Note
The gearbox identification characters also appear on the vehicle

data stickers.
1.2 Identification of rear final drive

The final drives 02D, 0AV and OBR are assigned to the 6 speed
gearbox 02Q for four-wheel drive.
Note
♦ The “Haldex coupling” is located in the rear final drive.

♦ The final drive and the “Haldex coupling” have separate oil
circulation systems.
♦ The final drives “02D/0AV” are fitted with the “Haldex coupling
of the 2nd generation”.
♦ The final drive “0BR” is fitted with the “Haldex coupling of the
4th generation”.
♦ The rear final drives “02D/0AV” and “0BR” have different “Hal‐
dex couplings” as well as different oils for the Haldex coupling.
♦ Both oils for the Haldex coupling must neither be mixed up nor
mixed, assignment ⇒ Electronic catalogue of original parts .
Assignment ⇒ page 4 .
Location on the final drive
Part number, identification characters of the final drive, production
date -arrow-.
2 Rep. Gr.00 - Technical data

OCTAVIA II 2004 ➤
Rear final drive 02D

-Arrow A- Part number of rear final drive
-Arrow B- Identification characters rear final drive
Note
The identification characters do not appear on all final drives. If

they do not appear, assignment ⇒ Electronic Catalogue of Orig‐
inal Parts .
-Arrow C- Production date

Example: HEZ 12 01 04
I I I I
characters year (2004)
ry.
Rear final drive 0AV

Note

inal Parts .

Example: HHJ 09 08 05
I I I I
ry.

OCTAVIA II 2004 ➤
Rear final drive 0BR

Note

inal Parts .

Example: KMC 09 09 08
I I I I
ry.
1.3 Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 6 speed 02Q
front-wheel-drive
Identification characters GRF HDV
Manufac‐ from 05.04 11.04
tured through 11.04 03.06
Assign‐ Engine 2.0 ltr./103 kW TDI PD 2.0 ltr./103 kW TDI PD
ment: 2.0 ltr./100 kW TDI PD 2.0 ltr./100 kW TDI PD
Ratio: Final drive for 1st gear through 69 : 20 = 3,450 69 : 20 = 3,450
4th gear
Final drive for 5th gear through 69 : 25 = 2,760 69 : 25 = 2,760
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 42 : 43 = 0,977 42 : 43 = 0,977
5th gear 39 : 40 = 0,975 39 : 40 = 0,975
6th gear 35 : 43 = 0,814 35 : 43 = 0,814
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
Filling capacity 2.3 litres
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch plate ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 107 mm

front-wheel-drive
Identification characters GVT JLU

OCTAVIA II 2004 ➤

front-wheel-drive
Assign‐ Engine 2.0 ltr./147 kW TFSI 2.0 ltr./103 kW TDI PD
ment: 2.0 ltr./100 kW TDI PD
4th gear
6th gear
Z2:Z1 1st gear 47 : 14 = 3,357 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 47 : 32 = 1,469 45 : 34 = 1,324
4th gear 45 : 41 = 1,098 42 : 43 = 0,977
5th gear 41 : 37 = 1,108 39 : 40 = 0,975
6th gear 38 : 41 = 0,927 35 : 43 = 0,814
Reverse gear 34 : 14 x 23 : 14 = 3.990 36 : 13 x 23 : 14 = 4.549

front-wheel-drive
Identification characters JLW JMA
ment:
4th gear
6th gear
Z2:Z1 1st gear 47 : 14 = 3,357 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 47 : 32 = 1,469 45 : 34 = 1,324
4th gear 45 : 41 = 1,098 34 : 37= 0,919
5th gear 41 : 37 = 1,108 37 : 41= 0,902
6th gear 38 : 41 = 0,927 28 : 37= 0,757
Reverse gear 34 : 14 x 23 : 14 = 3.990 36 : 13 x 23 : 14 = 4.549

front-wheel-drive
Identification characters KDN KDQ

OCTAVIA II 2004 ➤

front-wheel-drive
Assign‐ Engine 2.0 ltr./103 kW TDI PD 2.0 ltr./147 kW TFSI
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 47 : 14 = 3,357
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 47 : 32 = 1,469
4th gear 42 : 43 = 0,977 45 : 41 = 1,098
5th gear 39 : 40 = 0,975 41 : 37 = 1,108
6th gear 35 : 43 = 0,814 38 : 41 = 0,927
Reverse gear 36 : 13 x 23 : 14 = 4.549 34 : 14 x 23 : 14 = 3.990

front-wheel-drive
Identification characters KDS KNS
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 34 : 37= 0,919 42 : 43 = 0,977
5th gear 37 : 41= 0,902 39 : 40 = 0,975
6th gear 28 : 37= 0,757 35 : 43 = 0,814
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549

OCTAVIA II 2004 ➤

front-wheel-drive
Identification characters KNU KNY
ment:
4th gear
6th gear
Z2:Z1 1st gear 47 : 14 = 3,357 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 47 : 32 = 1,469 45 : 34 = 1,324
4th gear 45 : 41 = 1,098 34 : 37= 0,919
5th gear 41 : 37 = 1,108 37 : 41= 0,902
6th gear 38 : 41 = 0,927 28 : 37= 0,757
Reverse gear 34 : 14 x 23 : 14 = 3.990 36 : 13 x 23 : 14 = 4.549

front-wheel-drive
Identification characters KXX KXZ
tured through 05.10
Assign‐ Engine 2.0 ltr./103 kW TDI PD 2.0 ltr./125 kW TDI CR
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 42 : 43 = 0,977 34 : 37= 0,919
5th gear 39 : 40 = 0,975 37 : 41= 0,902
6th gear 35 : 43 = 0,814 28 : 37= 0,757
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
As of 06.09, the bearing of the reverse gear shift fork is modified.

OCTAVIA II 2004 ➤

front-wheel-drive
Identification characters KZS LHD
tured through
Assign‐ Engine 2.0 ltr./147 kW TFSI 2.0 ltr./103 kW TDI CR
ment:
4th gear
6th gear
Z2:Z1 1st gear 47 : 14 = 3,357 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 47 : 24 = 1,958
3rd gear 47 : 32 = 1,469 44 : 35 = 1,257
4th gear 45 : 41 = 1,098 40 : 46 = 0,870
5th gear 41 : 37 = 1,108 36 : 42 = 0,857
6th gear 38 : 41 = 0,927 33 : 46 = 0,717
Reverse gear 34 : 14 x 23 : 14 = 3.990 36 : 13 x 23 : 14 = 4.549

four-wheel drive
Identification characters FWZ JLS
Assignment: Engine 1.9 ltr./77 kW TDI PD 1.9 ltr./77 kW TDI PD
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 41 : 45 = 0,911 41 : 45 = 0,911
5th gear 37 : 41 = 0,902 37 : 41 = 0,902
6th gear 34 : 45 = 0,756 34 : 45 = 0,756
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
Capacity manual gearbox 2.3 litres
Capacity angle gearbox 0,9 litres

OCTAVIA II 2004 ➤

four-wheel drive
Assignment rear final drive identification char‐ HEY, HHK, HVZ HVZ
acters

four-wheel drive
Identification characters JLR KDX
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 41 : 45 = 0,911 41 : 45 = 0,911
5th gear 37 : 41 = 0,902 37 : 41 = 0,902
6th gear 34 : 45 = 0,756 34 : 45 = 0,756
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
Filling capacity - angle gearbox 0,9 litres
Assignment, identification characters rear fi‐ HVZ JYP
nal drive

four-wheel drive
Identification characters KDL KNP
Assignment: Engine 2.0 ltr./103 kW TDI PD
Ratio: Final drive for 1st gear through 62 : 16 = 3,875
4th gear
Final drive for 5th gear through 62 : 20 = 3,100
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324
4th gear 41 : 45 = 0,911
5th gear 37 : 41 = 0,902
6th gear 34 : 45 = 0,756

OCTAVIA II 2004 ➤

four-wheel drive
Reverse gear 36 : 13 x 23 : 14 = 4.549
Assignment, identification characters rear fi‐ JYP KJT
nal drive

four-wheel drive
Identification characters KNQ KSC
Assignment: Engine 1.9 ltr./77 kW TDI PD 1.8 ltr./118 kW TFSI
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 47 : 32 = 1,469
4th gear 41 : 45 = 0,911 45 : 41 = 1,098
5th gear 37 : 41 = 0,902 41 : 37 = 1,109
6th gear 34 : 45 = 0,756 38 : 41 = 0,927
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
Assignment, identification characters rear fi‐ KJT KMC
nal drive

four-wheel drive
Identification characters KXU KXV
tured through 05.10
4th gear

OCTAVIA II 2004 ➤

four-wheel drive
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 48 : 23 = 2,087
3rd gear 45 : 34 = 1,324 45 : 34 = 1,324
4th gear 41 : 45 = 0,911 41 : 45 = 0,911
5th gear 37 : 41 = 0,902 37 : 41 = 0,902
6th gear 34 : 45 = 0,756 34 : 45 = 0,756
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549
Assignment, identification characters rear fi‐ KMC, MMK
nal drive

four-wheel drive
Identification characters LHC LNN
tured through
Assignment: Engine 1.8 ltr./118 kW TFSI 1.6 ltr./77 kW TDI CR
1.8 ltr./112 kW TFSI
4th gear
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769 49 : 13 = 3,769
2nd gear 48 : 23 = 2,087 47 : 24 = 1,958
3rd gear 47 : 32 = 1,469 44 : 35 = 1,257
4th gear 45 : 41 = 1,098 40 : 46 = 0,869
5th gear 41 : 37 = 1,109 36 : 42 = 0,857
6th gear 38 : 41 = 0,927 33 : 46 = 0,717
Reverse gear 36 : 13 x 23 : 14 = 4.549 36 : 13 x 23 : 14 = 4.549

OCTAVIA II 2004 ➤

four-wheel drive
Assignment, identification characters rear fi‐ KMC, MMK
nal drive

four-wheel drive
Identification characters LNM
Manufac‐ from 06.10
tured through
Assignment: Engine 2.0 ltr./103 kW TDI CR
Ratio: Final drive for 1st gear through 69 : 16 = 3,875

4th gear
Final drive for 5th gear through 69 : 20 = 3,1
6th gear
Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 47 : 24 = 1,958
3rd gear 44 : 35 = 1,257
4th gear 40 : 46 = 0,870
5th gear 36 : 42 = 0,857
6th gear 33 : 46 = 0,717
Reverse gear 36 : 13 x 23 : 14 = 4.549
Assignment, identification characters rear fi‐ MMK
nal drive
Rear final drive 02D 0AV

Identification characters HEY HHK
tured
to 11.04 11.05
ment
Ratio Z2:Z1 27 : 17 = 1,588
Capacity final drive 0,925 litres
Capacity Haldex coupling 0,850 litres
Changing capacity Haldex coupling 0,720 litres

OCTAVIA II 2004 ➤
Rear final drive 02D 0AV

Change interval ⇒ Maintenance ; Octavia II
Assignment, identification characters gearbox FWZ FWZ
Note
Rear final drive 0AV

Identification characters HVZ JYP
tured
to 05.07 12.07
ment 2.0 ltr./103 kW TDI PD 2.0 ltr./103 kW TDI PD
Ratio Z2:Z1 27 : 17 = 1,588
Assignment, identification characters gearbox FWZ, JLS, JLR KDL, KDX
Note
Rear final drive 0AV 0BR

Identification characters KJT KMC
tured
to 05.08 11.09
Assign‐ Engine 1.9 ltr./77 kW TDI PD
ment 2.0 ltr./103 kW TDI PD
Ratio Z2:Z1 27 : 17 = 1,588

OCTAVIA II 2004 ➤
Rear final drive 0AV 0BR

Assignment, identification characters gearbox KNP, KNQ KNP, KNQ, KXV, KXU
Note

Identification characters KMC KMC
tured
to 11.09 11.09
ment 1.8 ltr./112 kW TFSI
Ratio Z2:Z1 27 : 17 = 1,588
Assignment, identification characters gearbox KSC, LHC LNN
Note

Identification characters MMK MMK
tured
to
ment 1.8 ltr./112 kW TFSI 1.9 ltr./77 kW TDI PD
2.0 ltr./103 kW TDI PD
2.0 ltr./103 kW TDI CR

OCTAVIA II 2004 ➤

Ratio Z2:Z1 27 : 17 = 1,588
Assignment, identification characters gearbox LHC LNN, KXV, KXU, LNM
Note

OCTAVIA II 2004 ➤
2 Overview of Transmission System
2.1 Front-wheel-drive
-Arrows- in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft 5th, 6th gear/
reverse gear
6 - Output shaft gears 1
through 4
7 - Differential gear
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

OCTAVIA II 2004 ➤
2.2 Four-wheel drive

-Arrows- in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft 5th/6th gear/
reverse gear
through 4
7 - Front differential gear
8 - Angle gearbox
9 - Propshaft
10 - Haldex coupling
11 - Rear final drive
12 - Rear differential gear
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Front final drive
W1 - Drive chain of the angle
gearbox
W2 - Drive chain of the rear fi‐
nal drive
2. Overview of Transmission System 17

OCTAVIA II 2004 ➤
3 General repair information

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 operations
- which are otherwise listed several times at numerous points in
the workshop manual - are summarized under the term “compo‐
nents” ⇒ page 18 . They apply to this workshop manual.
3.1 Contact corrosion!

♦ The gearbox housing and the clutch housing are made out of
magnesium.
♦ Bolts and other components that come into direct contact with
the gearbox have a surface with varying finishes in relation to
it.
♦ The use of substitute components causes contact corrosion
(screws, nuts, washers ...). The gearbox housing and the
clutch housing are damaged.
♦ Generally fit parts which are indicated in the ⇒ Electronic
Catalogue of Original Parts .
3.2 Components
Gearbox
♦ When installing the manual gearbox, ensure the dowel
sleeves are correctly located between the engine and gear‐
box.
♦ When assembling mounts as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ When replacing the gearbox, inspect the gear oil level in the
manual gearbox (top up if necessary) ⇒ page 100 .
♦ Filling capacity ⇒ page 4 .
♦ Oil specification ⇒ Electronic Catalogue of Original Parts .
Angle gearbox (four-wheel drive)
♦ The angle gearbox is screwed on laterally to the manual gear‐
box and equipped with its own closed oil supply.
♦ Inspect gear oil level (top up oil if necessary) ⇒ page 109 .
Rear final drive
♦ When replacing the rear final drive, inspect the oil level in the
final drive ⇒ page 306 and the oil level in the Haldex coupling
(top up with oil if necessary) ⇒ page 300 .
♦ When installing waxed carriers and components, the contact
surfaces must be cleaned. Contact surfaces must be free of
wax and grease.

OCTAVIA II 2004 ➤
Note

4th generation”.
Targeted fault finding, Vehicle self-diagnosis and Measuring

method
♦ Before repairing the Haldex coupling, try to determine the ori‐
gin of the damage as accurately as possible using the ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051 in
the functions “Targeted fault finding”, “Vehicle self-diagnosis”
and “Measuring method”.
Sealant
♦ Thoroughly clean the contact surfaces of the housing before
applying the silicone sealant.
♦ Apply sealant AMV 188 200 03 evenly and not too thick.
Gasket rings, O-rings, gaskets
♦ Always replace gasket rings, O-rings and gaskets ⇒ Elec‐
tronic Catalogue of Original Parts .
♦ After removing gaskets, check the contact surface in the hous‐
ing or shaft for burrs or damage which occured during the
assembly.
♦ Radial shaft seals - before mounting lightly oil at outside di‐
ameter and fill half the space between the sealing lips
-arrow- with sealing grease -G 052 128 A1- .
♦ The open side of the sealing rings is turned towards the fluid
to be sealed.
♦ Press in new gasket ring in such a way that the sealing lip is
not located on the same point as the sealing lip of the old gas‐
ket ring (use tolerance for insertion depth).
♦ Before inserting lightly oil the O-rings, in order to prevent the
rings being squashed during installation.
♦ Inspect the oil level after replacing the gaskets and gasket
rings.
Locking elements
3. General repair information 19

OCTAVIA II 2004 ➤
♦ Do not over-tension the circlips.

♦ Always replace damaged or over-tensioned circlips ⇒ Elec‐
tronic Catalogue of Original Parts .
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting location: slot longitudinally to power
flow.
Screws, nuts
♦ Slacken the bolts and nuts against the tightening sequence.
♦ Slacken and tighten screws or fixing nut of covers and hous‐
ings without tightening sequence diagonally across in stages.
♦ Replace the self-locking screws and nuts.
♦ Tightening torques apply for non-oiled nuts and bolts.
♦ Clean the threaded holes into which self-locking screws or
screws with locking agent were screwed in (using e.g. a screw-
tap). Otherwise there is a risk that the bolts will shear at the
next disassembling.
♦ It is important to ensure at all bolted connections that the con‐
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
Bearings
♦ New taper roller bearings are fitted as supplied and do not
require any additional lubrication.
♦ Insert moist all bearings (except taper roller bearings) in the
gearbox with gear oil.
♦ Before installing, heat the inner rings of the tapered-roller
bearings on a heating plate or with the induction heater unit ,
e.g. -VAS 6414- , to approx. 100°C. Press in axial and play-
free up to the stop.
♦ Do not mix up the outer and inner races of bearings of the
same size.
♦ Always jointly replace tapered-roller bearings on the same
shaft and use products of the same manufacturer.
♦ Always position needle bearing with the lettered side (thicker
end) towards the drift pin.
Shims
♦ Gauge shims at several points with a micrometer. Different

tolerances allow to select the required thickness for each
washer very precisely.
♦ Inspect for burrs and damage.
♦ Install only adjusting washers which are in perfect condition.
Synchronizer rings

OCTAVIA II 2004 ➤
♦ These are not interchangeable. If re-using, allocate synchron‐

izer rings to the same sliding gear.
♦ Inspect for wear, replace if necessary ⇒ Electronic Catalogue
of Original Parts .
♦ Check grooves -arrow 1- on synchronizer ring -A- or inner ring
for flattened parts (grooves are worn).
♦ On the installed intermediate ring -B-, check outer -arrow 2- or
inner -arrow 3- contact surface for traces of scoring and fric‐
tion.
♦ Check the cone of the sliding gear for traces of scoring and
friction.
♦ Oil with gear oil before installing.
Gear pinions and synchronizer body
♦ Clean and heat on a heating plate or with the induction heater
unit e.g. -VAS 6414- to approx. 100°C before pressing on.
♦ When assembling, press up to the stop until there is no axial
play.
♦ Check fitting position.
Sliding gears
♦ Inspect wheels 1st to 6th gear for small axial play or clearance
after installation.
Clutch control
♦ Do not tilt the clutch pressure plate, release or tighten in small
stages crosswise
♦ If the clutch pedal does not return to its initial position after the
coupling procedure - clutch pedal in home position - the clutch
control must be bled (further measures ⇒ page 35 ).
♦ In order to reduce unpleasant odours if the clutch is burnt,
thoroughly clean the clutch housing as well as the flywheel and
the engine on the side of the gearbox.
3. General repair information 21

OCTAVIA II 2004 ➤
30 – Clutch
1 Repairing clutch control
1.1 Overview
Note
♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System
⇒ Rep. Gr. 27 .
♦ Grease all bearing and contact surfaces with grease -G 000 450 02- .
I - Summary of components -
Foot controls ⇒ page 23
II - Summary of components -
Hydraulics ⇒ page 33
22 Rep. Gr.30 - Clutch

OCTAVIA II 2004 ➤
1.2 Summary of components - Foot controls
1 - Front wall
❑ with mount for bracket
2 - Gasket
❑ replace ⇒ Electronic
Catalogue of Original
Parts
❑ between bracket and
front wall
❑ self-adhesive
❑ glue to bracket
3 - Bearing bracket
❑ for support of clutch
pedal
❑ removing and installing
⇒ page 27
4 - Screw
5 - Over-centre helper spring
⇒ page 24
6 - Bushing
7 - Bearing bolt
8 - Clutch pedal
⇒ page 25
9 - Support
⇒ page 25
10 - Gasket
Parts
❑ between master cylinder and bracket
11 - Master cylinder
❑ removing and installing after removing the bracket ⇒ page 30
❑ test tightness ⇒ page 35
12 - Clutch position sender -G476-
❑ removing and installing ⇒ page 30
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
13 - Clamp
❑ to remove and install the tube-hose line and/or plastic line pull out retaining clip up to the stop
14 - Tubing
❑ out of rubber
❑ as of 12.05 on certain vehicles out of plastic ⇒ page 33
❑ Do not use hose clamp -MP7–602-
15 - 20 Nm
❑ 3 pieces
1. Repairing clutch control 23

OCTAVIA II 2004 ➤
❑ self-locking
❑ for bracket on front wall
❑ replace ⇒ Electronic Catalogue of Original Parts
16 - 25 Nm
17 - Stop
❑ for the clutch pedal
1.3 Removing and installing the over-centre

helper spring
Special tools and workshop equipment required
♦ Release tool -T10178-
Removing
– Push the driver seat as far as possible towards the rear and
position the steering wheel in the highest position.
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work ⇒ Rep. Gr. 70 .
– Unscrew crash strut -1- in front of the clutch pedal -2-.
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
Note
The clutch pedal remains hanging on the actuating rod of the

master cylinder.
– Swivel clutch pedal slightly downwards and remove over-cen‐

tre helper spring -4- from the bracket.
Install
Installation is performed in the reverse order, pay attention to the
following points:
Note
Replace self-locking nut.

OCTAVIA II 2004 ➤
– Insert over-centre helper spring -2- from above into the bracket
and while doing so hold the spring end in the fitting position
using the release tool -T10178- .
– Insert bearing bolt of clutch pedal into the step bearing of the
over-centre helper spring.
– Press on clutch pedal -1- slightly, slide through screw and
tighten self-locking nut.
– Screw on crash strut -1- in front of the clutch pedal -2-.

– Install lower part of the dash panel insert on the driver's side
Tightening torques
Component Nm
Clutch pedal to bearing bracket ⇒ Item 16 (page 24)
Crash strut to bracket/steering column 9
1.4 Removing and installing the clutch pedal

♦ Pliers -T10005-
♦ Release tool -T10178-
Removing
– Push the driver seat as far as possible towards the rear and
position the steering wheel in the highest position.

OCTAVIA II 2004 ➤
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
– Swivel clutch pedal slightly forwards and remove over-centre
helper spring -4- from the bracket.
– Release support of actuating rod of master cylinder with the

pliers - T10005- .
– Remove clutch pedal.
Install
following points:
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Press support into the clutch pedal until it audibly clicks into
place.

OCTAVIA II 2004 ➤
– Insert over-centre helper spring from above into the bracket

and while doing so hold the the spring end in the fitting position
using the release tool -T10178- .
– Insert bearing bolt of clutch pedal into the step bearing of the
over-centre helper spring.
– Press on clutch pedal slightly, slide through screw and tighten
self-locking nut.

Tightening torques
Component Nm
1.5 Removing and installing bracket

♦ Hose clamp -MP7-602 (3094)-
Removing
Note
If the battery earth strap is disconnected and connected, carry out

additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System ⇒ Rep. Gr. 27 .
– Remove air filter ⇒ Engine ⇒ Rep. Gr. 23 or ⇒ Engine ⇒
Rep. Gr. 24 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .

OCTAVIA II 2004 ➤
Note
♦ When performing the following work, make sure that no brake

fluid comes into contact with the frame side rail or the gearbox.
If this is the case, these points must be cleaned thoroughly.
♦ Lay a cloth below the master cylinder.
– Pinch off return hose to master cylinder with hose clamp -

MP7-602 (3094)- (if the return hose is made out of plastic, do
not use the hose clamp -MP7–602- , otherwise the return hose
can get damaged).
– Detach return hose -3- at master cylinder (detach plastic return

hose at master cylinder and close with a suitable tool e.g.
closing tool -T10249/1- ).
– Unlock locking clip -2- with a screwdriver and detach tube-
hose line and/or plastic line -1- at master cylinder.
– Clip off clutch position sender -G476- at master cylinder
-arrow- and remove with attached connector -4-.
Note
When working in the footwell, protect the floor carpet with cloths
from escaping brake fluid.

OCTAVIA II 2004 ➤
– Unscrew the nuts -2-.

– Remove bracket -1-.
Install
following points:
Note
♦ Replace self-locking nuts.

♦ Replace damaged gasket rings ⇒ Electronic Catalogue of
Original Parts .
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .

– Press in tube-hose line and/or plastic line -1- with gasket ring
-2- onto the connection of the master cylinder -4-, until the
locking clip -3- is heard to click into position.
– For testing pull on the line -1-.
– Bleed the clutch control ⇒ page 36 .
– Install battery tray and battery ⇒ Electrical System ⇒ Rep.
Gr. 27 .
– Install air filter ⇒ Engine ⇒ Rep. Gr. 23 or ⇒ Engine ⇒ Rep.
Gr. 24 .
Note
After the battery earth strap is disconnected and re-connected,

carry out additional operations ⇒ Electrical System ⇒ Rep. Gr.
27 .
– Connect earth strap of battery ⇒ Electrical System ⇒ Rep.

Gr. 27 .
Tightening torques
Component Nm

OCTAVIA II 2004 ➤
1.6 Removing and installing the master cyl‐

inder
Removing
– Removing bracket ⇒ page 27 .
– Release support of actuating rod of master cylinder with the
pliers - T10005- .
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal forwards.
♦ Length of spacer = approx. 40 mm
– Release release pin -B- and pull master cylinder out of bracket
-arrow 1- and -arrow 2-.
Install
• Move clutch pedal up to the stop into home position.
– Attach support -2- to the actuator rod -1- of the master cylinder.

OCTAVIA II 2004 ➤
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal into operating position.
♦ Length of spacer = approx. 40 mm
– Lock master cylinder at bracket -arrow 1- and -arrow 2-.
– Press actuating rod -1- of master cylinder into direction of ar‐

row, until the support -2- locks audibly into the clutch pedal.
– Installing bracket ⇒ page 27 .
1.7 Removing and installing clutch position

sender -G476-
Removing
Note

27 .

Rep. Gr. 24 .
– Remove battery, battery cover and battery tray ⇒ Electrical
System ⇒ Rep. Gr. 27 .

OCTAVIA II 2004 ➤
If a tube-hose line and/or plastic line -1- is installed with a round

component directly below the master cylinder, the tube-hose line
and/or plastic line must be removed.
Note
When performing the following work, make sure that no brake

fluid comes into contact with the frame side rail or the gearbox. If
this is the case, these points must be cleaned thoroughly.
– Pinch off return hose to master cylinder with hose clamp -

MP7-602 (3094)- (if the return hose is made out of plastic, do
not use the hose clamp -MP7–602- , otherwise the return hose
can get damaged).
– Detach return hose -3- at master cylinder (detach plastic return

hose at master cylinder and close with a suitable tool e.g.
closing tool -T10249/1- ).
– Separate electrical plug connection -4-.
– Clip off clutch position sender -G476- at master cylinder
-arrow- and remove.
Install
following points:
Note
♦ Replace damaged gasket rings ⇒ Electronic Catalogue of

Original Parts .
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .
If the tube-hose line and/or plastic line was removed:

OCTAVIA II 2004 ➤
– Press in tube-hose line and/or plastic line -1- with gasket ring
-2- onto the connection of the master cylinder -4-, until the
locking clip -3- is heard to click into position.
– Check that it locks in place correctly by pulling on the line
-1-.
– Install battery tray and battery ⇒ Electrical System ⇒ Rep.
Gr. 27 .
Gr. 24 .
Note

27 .
– Connect earth strap of battery ⇒ Electrical System ⇒ Rep.

Gr. 27 .
1.8 Summary of components - Hydraulics
1 - Brake fluid reservoir

❑ test tightness
⇒ page 35
2 - Spring strap clamp
❑ not fitted to all vehicles
3 - Tubing
❑ out of rubber
❑ as of 12.05 on certain
vehicles out of plastic
⇒ page 35
❑ Do not use hose clamp -
MP7–602-
❑ test tightness
⇒ page 35
4 - Master cylinder
⇒ page 30
❑ test tightness
⇒ page 35
5 - Clamp
❑ to remove and install the
tube-hose line and/or
plastic line pull out re‐
taining clip up to the stop
6 - Gasket ring/O-ring
❑ pull onto line connection
❑ insert with brake fluid
❑ Gasket rings/O-rings
adapted to the material
of the line connection
⇒ page 35
❑ Assignment ⇒ Electron‐

OCTAVIA II 2004 ➤
ic Catalogue of Original
Parts
7 - Support
8 - Clutch pedal
9 - 20 Nm
❑ 3 pieces
❑ for bracket on front wall
10 - Tube-hose line
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ Remove battery and battery tray for removing ⇒ Electrical System ⇒ Rep. Gr. 27
11 - Support
❑ Mounted at the structure
❑ for tube-hose line pos. 10
❑ Difference between the supports ⇒ page 35
12 - Plastic line
❑ Do not use hose clamp -MP7–602-
❑ Remove battery and battery tray for removing ⇒ Electrical System ⇒ Rep. Gr. 27
13 - Support
❑ Mounted at the structure
❑ for plastic line Pos. 12
❑ Difference between the supports ⇒ page 35
14 - Gasket ring/O-ring
❑ Gasket rings and O-rings adapted to the material of the line connection ⇒ page 35
15 - Breather
❑ pay attention to different versions, assign via ⇒ Electronic Catalogue of Original Parts
16 - Clamp
❑ to remove and install the tube-hose line or plastic line or the breather pull out retaining clip up to the stop
17 - Vent valve
❑ Bleed the clutch control ⇒ page 36
❑ pay attention to different versions, assign via ⇒ Electronic Catalogue of Original Parts
18 - Dust cap
19 - Slave cylinder
❑ can only be replaced without removing gearbox

OCTAVIA II 2004 ➤
20 - Gearbox
Gasket rings / O-rings for tube-hose lines and/or plastic line

♦ -1- Line connection with circular slot -arrow 1-
♦ -2- Line connection with collar -arrow 2-
As of 12.05 - on certain vehicles plastic return hose -1-

♦ Gaskets -2- must be present on the return hose.
♦ Do not use hose clamp -MP7–602-
Difference between the supports

Dimension Version of the line
“a” mm
8 Plastic line
6 Tube-hose lines
1.9 Test of hydraulic clutch control

• The pedal actuation must not be obstructed by a moved or an
additional foot mat.

OCTAVIA II 2004 ➤
– First of all check the brake fluid level in the brake fluid reser‐
voir.
Note
♦ The clutch hydraulic is connected to one of the chambers

-arrow 2- of the brake fluid reservoir by the return hose
-arrow 1-.
♦ If there is no or little brake fluid in this chamber, there is a leak
in the system.
♦ Bleed the clutch control if necessary ⇒ page 36 .
– Subsequently check the following components of the hydraulic

clutch control for external leak:
♦ Return hose between brake fluid reservoir and master cylinder

♦ Master cylinder
♦ Tube-hose line or plastic line between master and slave cyl‐
inder
♦ Connection points (plug and screw connections) also in a non-
visible area
♦ Bleeder -A- (slave cylinder is located in the clutch housing)
Note
♦ Symptoms of an external leak are, amongst others, traces of

brake fluid below the gearbox or on the noise insulation under
the gearbox.
♦ Check the correct routing of the plastic line between the mas‐
ter and slave cylinder. The line must not be kinked or trapped.
– Subsequently depress the clutch pedal carefully, at the same

time hold the foot controls in five different positions for approx.
20 seconds over the entire distance the pedal has to travel.
While doing so, a second person must check if fluid is leaking
from the components of the hydraulic clutch control
⇒ page 36 . At the same time the first person must check if the
clutch pedal falls through on its own while being held.
– If necessary remove gearbox. Remove slave cylinder -A- and

check for brake fluid leak.
Observe that the supply line can be separated on certain slave
cylinders -A- -arrow-.
1.10 Bleed the clutch control

♦ Brake filling and bleeding device e.g. -VAS 5234- or -ROM‐
ESS S15-

OCTAVIA II 2004 ➤
Note
A pre-filling of the system is not necessary!
Brake fluid specification ⇒ Chassis ⇒ Rep. Gr. 47 .

Rep. Gr. 24 .
– Connect the brake filling and bleeding device .
To bleed use ventilation hose -A-.
– Then connect ventilation hose with the drip bottle of the brake
bleeding device.
– Fit the ventilation hose -A- onto the bleeder -arrow-.
– Activate system with a pressure of 0.2 MPa (2 bar).
– Open vent valve.
Note
On certain vehicles the vent valve can be opened by hand. To do

so, turn the vent valve to the left by 180° as far as the stop.
– Allow approx. 100 cm3 of brake fluid to flow out.

– Close vent valve.
– Activate foot controls forcefully from stop to stop between 10
and 15 times.
– Open vent valve.
– Allow approx. 50 cm3 more brake fluid to flow out.
– Close vent valve.
– After completing the bleeding procedure activate the clutch
pedal repeatedly.
Gr. 24 .

OCTAVIA II 2004 ➤
2 Repairing clutch control
2.1 Summary of components
1 - Gearbox
2 - Gasket ring for drive shaft
❑ replace ⇒ page 40
3 - Slave cylinder with release
bearing
❑ form one unit, can only
be replaced together
❑ Do not wash the bear‐
ing, just wipe clean
❑ replace noisy bearings
together with slave cyl‐
inder
❑ on certain slave cylin‐
ders separated supply
line ⇒ page 39
Parts
⇒ page 39
4 - Screw
❑ for metal slave cylinder:
12 Nm (without locking
agent)
❑ for plastic slave cylin‐
der: 15 Nm (with locking
agent)
❑ 3 pieces
Parts
❑ carefully tighten in small
stages crosswise so
that the screw-down
eyes of the slave cylin‐
der do not break off
5 - O-ring

OCTAVIA II 2004 ➤
Slave cylinder with separated supply line

The supply line is separated on certain slave cyclinders -A- in the
area of the -arrow-.
Assignment ⇒ Electronic Catalogue of Original Parts .
2.2 Remove and install slave cylinder with

clutch release bearing
Note
Slave cylinder and clutch release bearing form one unit and can
only be replaced together.
Removing
– Removing gearbox - Front-wheel-drive ⇒ page 81 .
– Removing gearbox - Four-wheel drive ⇒ page 88 .
– Unlock locking clip -2- with a screwdriver and detach bleeder
-4- from slave cylinder -1-.
– Remove slave cylinder with release bearing -arrows-.

Install
following points:
• The fixing screws for the slave cylinder must only be tightened
in small stages.
Otherwise there is the risk that the tabs with the bolt-holes break
off.
– Tighten slave cylinder with release bearing to tightening tor‐
que.

OCTAVIA II 2004 ➤
– Inspect the O-ring -3- at slave cylinder for damage.

– Press in the bleeder -4- at the connection of the slave cylinder
-1- until the locking clip -2- clicks into place.
– For checking pull at bleeder -4-.
– Installing the gearbox ⇒ page 97 .
Tightening torque
Component Nm
Slave cylinder to gearbox ⇒ Item 4 (page 38)
2.3 Replace gasket ring for drive shaft

♦ Thrust piece -T40008-
♦ Extraction hook -T20143/1-
♦ Sealing grease -G 052 128 A1-
Removing
– Remove slave cylinder with release bearing ⇒ page 39 .
– Lever out gasket ring for drive shaft with ejection hook -
T20143/1- .
Note
Do not damage contact surface for shaft seal on the drive shaft.
Install
– Fill half the space between the sealing lip and dust lip with
sealing grease -G 052 128 A1- .
– Slightly moisten the outer circumference of the gasket ring with
gearbox oil.

OCTAVIA II 2004 ➤
– Insert the gasket ring for the drive shaft until flush.
– Install slave cylinder with release bearing ⇒ page 39 .

OCTAVIA II 2004 ➤
3 Repairing clutch
♦ Counterholder -MP1-223 (3067)-
♦ Centering mandrel -T10097-
♦ Grease for plug serration of clutch disc -G 000 100-
3.1 Summary of components - Repairing the clutch make “Sachs”
Note
♦ Before replacing the clutch disc and pressure plate fault finding power transmission - observe complaints
of the clutch and clutch control ⇒ page 49 .
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ Assign the clutch disc and pressure plate in accordance with engine identification characters ⇒ Electronic
♦ The two-mass flywheel, pressure plate and clutch disc are assigned to each other and must not be installed
together with components from other manufacturers.
1 - The two-mass flywheel

❑ make sure the centering
pins are tight
❑ The locating face for the
clutch lining must be
free from grooves, oil
and grease
❑ Observe removal in‐
structions for two-mass
flywheel ⇒ engine ⇒
Rep. Gr. 13
⇒ Engine ⇒ Rep. Gr.
13
2 - Clutch disc
❑ Assign the diameter via
the ⇒ Electronic cata‐
logue of original parts .
⇒ page 43
❑ must only be replaced
together with pressure
plate
❑ Fitting position
⇒ page 44
3 - Pressure plate
❑ assign ⇒ Electronic
Parts
❑ with resetting mecha‐
nism
❑ Distinguishing feature
⇒ page 43
⇒ page 43

OCTAVIA II 2004 ➤
❑ Check the extremities of the membrane spring ⇒ page 44
❑ Check feather joints and riveted joints ⇒ page 44
❑ must only be replaced together with clutch disc Pos. 2
4 - Screw M6 - 13 Nm; screw M7 - 20 Nm
❑ release or tighten in small stages crosswise
3.2 Removing and installing clutch make

“Sachs”
3.2.1 Removing
In order to avoid a deformation of the pressure plate when re‐
moving it (this leads to jerking during start-up), the pressure plate
must be loosened as follows:
– Insert counterholder -MP1-223- to slacken the bolts.
– Release bolts in small stages crosswise.
• When unscrewing, the stop must slacken -2- together with the
bolt -1-.
– If the stop does not slacken: Press bolt in the direction of the
flywheel.
– Remove pressure plate and clutch disc.
3.2.2 Install
following points:
Note
♦ Replace pressure plate and clutch disc together.

♦ Assign the pressure plate and clutch disc in accordance with
the engine identification characters via the ⇒ Electronic cata‐
♦ The two-mass flywheel, pressure plate and clutch disc are as‐
signed to each other and must not be installed together with
components from other manufacturers.
Distinguishing feature self-adjusting clutch type “Sachs”

♦ Pressure plate with stop (position sensor) -arrow-.
3. Repairing clutch 43
OCTAVIA II 2004 ➤
Fitting location of clutch disc

• Legend “side of gearbox” and the protruding spring cage
points to the gearbox.
Check the extremities of the membrane springs

• Wear is allowed up to half the membrane spring thickness
-arrows-.
Check feather joints and riveted joints

– Check the feather joints between pressure plate and cover for
cracks as well as the riveted joints for firm seating.
• Pressure plate with damaged feather joints or with loose rive‐
ted joints -arrows- must be replaced.
Note
♦ Replace the clutch discs and pressure plates if the riveting is

damaged or loose.
♦ Always replace pressure plate and clutch disc together.
♦ Clean the drive shaft serration and hub serration on used
clutch discs, remove corrosion. Apply a very thin layer of
grease for plug serration of clutch disc -G 000 100- onto the
serration. Subsequently move the clutch disc up and down on
the drive shaft until the hub fits smoothly on the shaft. Remove
all excess grease.
♦ 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.
♦ The thrust surface of the pressure plate and the clutch disc
lining must fully rest against the flywheel. Only then may the
fixing screws be inserted.

OCTAVIA II 2004 ➤
– When installing, insert the counterholder -MP1-223 (3067)- for

tightening the screws.
– Place the pressure plate onto the centering pins.
– Use centering mandrel -T10097- for centering the clutch disc.
In order to avoid a deformation of the pressure plate when instal‐

ling it (this leads to jerking during start-up), the pressure plate
must be installed as follows:
– Pay attention that the stop bolt (position sensor) -arrow- can
move freely.
– Screw in all the screws by hand uniformly, until the bolt head
rests against the pressure plate.
– Tighten the screws gradually and crosswise so as not to dam‐
age the centering holes on the pressure plate and the center‐
ing pins of the flywheel, while doing so the stop bolt -arrow-
must not be lifted up from the pressure plate.
– Tighten all 6 screws gradually to tightening torque
⇒ Item 4 (page 43) .
OCTAVIA II 2004 ➤
3.3 Summary of components - Repairing the clutch make “LuK”
Note
♦ Before replacing the clutch disc and pressure plate fault finding power transmission - observe complaints
of the clutch and clutch control ⇒ page 49 .
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ Assign the clutch disc and pressure plate in accordance with engine identification characters ⇒ Electronic
♦ The two-mass flywheel, pressure plate and clutch disc are assigned to each other and must not be installed
together with components from other manufacturers.
1 - The two-mass flywheel

❑ make sure the centering
pins are tight
❑ The locating face for the
clutch lining must be
free from grooves, oil
and grease
❑ Observe removal in‐
structions for two-mass
flywheel ⇒ engine ⇒
Rep. Gr. 13
⇒ Engine ⇒ Rep. Gr.
13
2 - Clutch disc
❑ Diameter: assign ⇒
Electronic Catalogue of
Original Parts
⇒ page 47
❑ must be only replaced
together with “SAC”
pressure plate Pos. 3
⇒ page 47
3 - “SAC”-Pressure plate
❑ “SAC” (Self Adjusting
Clutch) means “self-ad‐
justing clutch”
❑ assign ⇒ Electronic
Parts
⇒ page 47
❑ Check the extremities of
the membrane spring ⇒ page 47
❑ Check feather joints and riveted joints ⇒ page 47
❑ Only check the position of the resetting mechanism on new pressure plates ⇒ page 48
❑ must only be replaced together with clutch disc Pos. 2
4 - Screw M6 - 13 Nm; screw M7 - 20 Nm
❑ release or tighten in small stages crosswise

OCTAVIA II 2004 ➤
3.4 Removing and installing clutch make

“LuK”
3.4.1 Removing
In order to avoid a deformation of the pressure plate when re‐
moving it (this leads to jerking during start-up), the pressure plate
must be loosened as follows:
– Insert counterholder -MP1-223 (3067)- to slacken the bolts.
– Release bolts in small stages crosswise.
– Remove pressure plate and clutch disc.
3.4.2 Install
following points:
Note

♦ The two-mass flywheel, pressure plate and clutch disc are as‐
signed to each other and must not be installed together with
components from other manufacturers.
Fitting location of clutch disc

• Legend “side of gearbox” points to the gearbox.
Check the extremities of the membrane springs

• Wear is allowed up to half the membrane spring thickness
-arrows-.
OCTAVIA II 2004 ➤
Check feather joints and riveted joints

– Check feather joints -arrows A- for damage as well as riveted
joints -arrows B- for firm seating.
Only check the position of the resetting mechanism on new pres‐

sure plates
• Both edges -A- of the adjustment ring must be located be‐
tween both notches -arrows B-.
• If the adjustment ring adopts another position when the pres‐
sure plates are new, the pressure plate and the clutch disc
must not be installed.
• On used clutches the adjusting ring can also have another
position outside the notches.
Note
♦ Replace the clutch discs and pressure plates if the riveting is

damaged or loose.
♦ Clean the drive shaft serration and hub serration on used
clutch discs, remove corrosion. Apply a very thin layer of
grease for plug serration of clutch disc -G 000 100- onto the
serration. Subsequently move the clutch disc up and down on
the drive shaft until the hub fits smoothly on the shaft. Remove
all excess grease.
♦ 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.
♦ The thrust surface of the pressure plate and the clutch disc
lining must fully rest against the flywheel. Only then may the
fixing screws be inserted.

OCTAVIA II 2004 ➤
– When installing, insert the counterholder -MP1-223 (3067)- for

tightening the screws.
– Place the pressure plate onto the centering pins.
– Use the centering mandrel -T10097- for centering the clutch
disc.
In order to avoid a deformation of the pressure plate when instal‐
ling it (this leads to jerking during start-up), the pressure plate
must be installed as follows:
– Screw in all the screws by hand uniformly, until the bolt head
rests against the pressure plate.
– Tighten the screws gradually and crosswise so as not to dam‐
age the centering holes on the pressure plate and the center‐
ing pins of the flywheel.
– Tighten all 6 screws gradually to tightening torque
⇒ Item 4 (page 46) .
3.5 Fault finding power transmission - prob‐

lems with the clutch and clutch control
Note
Check hydraulic clutch control ⇒ page 35 .
Before each clutch repair, examine and reconstruct the complaint

of the customer. In each individual case, it must be determined if
indeed there are problems with the clutch or the incorrect setting
of the gearshift is cause for complaint.
Complaint Fault description Measure
Clutch pedal does not return to ini‐ ♦ Air in line system. – Vent air from the line system;
tial position top up with brake fluid.
♦ Line system, master or slave – Replace defective part, vent air
cylinder leaking. from the line system; top up with
brake fluid.
♦ Membrane spring of the pres‐ – Replace pressure plate.
sure plate broken.

Actuating force on the clutch pedal ♦ Over-centre helper spring de‐ – Replace over-centre helper
too high fective. spring.
♦ Clutch release force increased – Inform customer (higher release

due to wear of clutch linings. force with increased wear).
– Replace clutch disc, when the

distance base/rivet is below 0.1
mm.
♦ Pressure plate with wrong – Assign pressure plate via the ⇒
spring identification. Electronic catalogue of original
parts .
♦ Mechanical fault of the pressure – Replace defective parts.
plate/clutch disc.
OCTAVIA II 2004 ➤

♦ Clutch disc on the serration – Check serration of the hub for
sluggish/jams. damage (burrs), if necessary re‐
place clutch disc.
– Clean the hub and the drive

shaft serration from corrosion
and residues of lubricant and
grease with grease for plug ser‐
ration of clutch disc -
G 000 100- . Move clutch disc
back and forth, remove excess
grease.

Noises when operating the clutch ♦ Release bearing of the slave cyl‐ – Always replace noisy release
inder defective. bearing/slave cylinder.
♦ Contact surface (tips of mem‐ – Replace pressure plate.

brane spring) of the pressure
plate defective (bent, broken).– Check release bearing, replace
if necessary.
♦ Centre displacement of engine/ – Check dowel sleeves.
gearbox.
♦ Clutch disc installed the wrong – Correct installation.

way up.
♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒

Electronic catalogue of original
parts .

Scratch noises when the forward or ♦ Air in the system, clutch does – Bleed system; check system,
reverse gear is engaged, gearschift not separate fully. top up with brake fluid.
jams, hooks, is sluggish, shifting
not possible, clutch without opera‐
tion
♦ Master/slave cylinder, line is – Replace defective part, top up
leaking. with brake fluid, bleed system.
♦ The travel of the clutch pedal is – Inform customer.

not sufficent (carpet, foot mat
under the foot controls) clutch is
not fully depressed.
♦ Pressure plate uneven due to in‐ – Inspect parts, if necessary re‐

correct installation, clutch disc place, observe position of the
warped due to improper han‐ centering pins.
dling.
– If afterwards scratching still oc‐
curs, check the serration of the
clutch disc on the drive shaft for
ease of movement, if necessary
carry out gearbox repair.
♦ Tips of membrane spring broken – Replace pressure plate.
or bent (assembly fault).
– Check release bearing/slave
cylinder, replace if necessary.
– Check dowel sleeves.

OCTAVIA II 2004 ➤

♦ Clutch disc too thick. – Assign clutch disc via the ⇒
parts .
♦ Lining glued to the flywheel – Slightly rub down friction surfa‐
(long immobilization time, high ces of the clutch linings or re‐
humidity). place completely the severely
corroded parts.
♦ Clutch disc on the serration – Check serration of the hub for
sluggish/jams. Corroded hub, damage, if necessary replace
damaged during assembly. Hub clutch disc.
profile knocked out on one side.
– Remove corrosion and traces of
grease from hub and shaft.
Grease shaft with grease for
plug serration of clutch disc -
G 000 100- .
– Move clutch disc back and forth,

remove excess grease.
– Check position of dowel sleeves

on knocked out hub profile.
– Check release bearing/slave

cylinder and pressure plate, re‐
place if necessary.
♦ Lifting of pressure plate too low – Assign pressure plate via the ⇒
(wrong pressure plate installed). Electronic catalogue of original
parts .
♦ Displacement of engine/gear‐ – Insert dowel sleeves before
box too large (dowel sleeves gearbox has been fitted.
missing), support panel of clutch
plate bent through this. – Check clutch disc and pressure
plate for damage, if necessary
replace.
♦ Linings spalled off because of – Replace clutch disc. Inform cus‐
too high revs (shift back during tomer.
too high speed).
♦ When starting, linings are spal‐
led off through slipping for too
long a time.

Load change jolts when throttle is ♦ Suspension assembly too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic Catalogue
the engine speed of Original Parts replace if nec‐
essary.
♦ Irregular engine running. – Check engine setting, correct.
♦ Clutch disc with predamper is – Inform customer.

built in against gear rattling.
♦ Centre displacement of engine/ – Test dowel sleeves, replace if

gearbox. necessary.
OCTAVIA II 2004 ➤

Clutch slips through, no or bad pre‐ ♦ Wrong clutch disc, wrong pres‐ – Assign the clutch disc and pres‐
drive sure plate installed. sure plate via the ⇒ Electronic
catalogue of original parts .
♦ Clutch disc worn out, burnt, – Replace clutch disc.
pressure plate overheated,
scoring, pressure plate warped – Replace pressure plate.
through incorrect assembly,
contact pressure of the pressure – Inform customer.
plate too low, driving error, nat‐
ural wear.
♦ Clutch disc, pressure plate, fly‐ – Replace clutch disc.

wheel oily. Shaft seals of engine
or gearbox defective. Grease on – Clean contact surfaces of pres‐
the contact surfaces through ex‐ sure plate and flywheel.
cess greasing of the hub.
– Replace shaft seal, remove ex‐
cess grease from the drive shaft.
♦ Clutch disc installed the wrong – Correct installation, check
way up. clutch disc, replace if necessary.
♦ Flywheel depth too large or ex‐ – Assign the sealing flange via the
cess removal at the base of the ⇒ electronic catalogue of origi‐
thrust surface. nal parts .
– Inspect clutch disc, pressure

plate, replace if necessary.
♦ Slave cylinder leaking. – Replace slave cylinder.

Clutch grabbing, ♦ Air in the system. – Bleed system, check brake fluid
unit shaking level, check system for tight‐
ness.
– Replace defective part.

♦ Engine does not run clean. – Check engine setting, correct.
♦ Driving error, starting speed is – Inform customer.

too low.
♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒

parts .
♦ Assembly bearing too soft, – Check assembly bearing, if nec‐
knocked out. essary assign via the ⇒ Elec‐
tronic Catalogue of Original
Parts .
♦ Clutch lining, contact surface of – Check shaft seal of the gearbox
pressure plate and flywheel oily drive shaft or the crankshaft, re‐
(oil leakage from the clutch place if necessary.
housing).
– Replace clutch disc, clean pres‐
sure plate and flywheel.

OCTAVIA II 2004 ➤

♦ The contact surface of the pres‐ – Check the contact surface of the
sure plate lifts off only unilater‐ clutch lining at the flywheel,
ally due to the tilted release check pressure plate and mem‐
bearing of the slave cylinder. brane spring, replace pressure
plate if necessary.
♦ Housing of the pressure plate
warped when installed. Contact – Replace release bearing/slave
surface of the pressure plate lifts cylinder.
off only unilaterally.
♦ Drive schaft too heavily greased – Clean pressure plate and fly‐
(traces of grease on the clutch wheel free of grease, replace in
disc, pressure plate and fly‐ the event of damage (rattle
wheel). markings, traces of overheating,
scoring).
– Remove traces of grease from

hub and shaft, grease shaft with
grease for plug serration of
clutch disc -G 000 100- .
– Move clutch disc back and forth,

remove excess grease.

Acoustic knock “klack” when cou‐ ♦ Carrier earth/drive shaft is ac‐ – Inform customer.
pling celerated with sudden coupling.
The drive shaft serration of the
pinions in mesh knocks; for
clutch discs with predamper the
noise increases as the predam‐
per reaches the stop.

Noises in idle ♦ Torsional damper spring bro‐ – Replace clutch disc.
ken.
♦ Clutch disc without predamper – Assign clutch disc via the ⇒

installed (idle rattling). Electronic catalogue of original
parts .
♦ Pressure plate warped, broken, – Replace pressure plate.
imbalance.
♦ Irregular engine running. – Check engine setting, correct if

necessary.
♦ Displacement of engine/gear‐ – Insert dowel sleeves before
box too large (dowel sleeves gearbox has been fitted.
missing).
♦ Intermediate plate grinds at fly‐ – Insert intermediate plate on

wheel. sealing flange and push onto the
dowel sleeves.
OCTAVIA II 2004 ➤
34 – Control, housing
1 Repairing shift mechanism
1.1 Fitting location of shift mechanism

-Arrow A- Shift movement
-Arrow B- Selector movement
A - Shift cable
B - Selector cable
C - Heat shield
❑ take off before removing
the shift mechanism
1 - Gearshift lever
2 - Reversing lever
54 Rep. Gr.34 - Control, housing

OCTAVIA II 2004 ➤
Note
♦ After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical
System ⇒ Rep. Gr. 27 .
♦ Remove shift mechanism for replacing control cables ⇒ page 71 .
♦ Do not kink the control cables.
I - Summary of components -
Gearshift knob with shift lever
collar ⇒ page 56 .
Gearshift mechanism (up to
10.06) ⇒ page 58
Gearshift mechanism (as of
11.06) ⇒ page 60
III - Summary of components -
Control cables ⇒ page 66 .
1. Repairing shift mechanism 55

OCTAVIA II 2004 ➤
1.3 Summary of components - gearshift knob and cover
1 - Gearshift knob
❑ with collar
❑ The gearshift knob and
collar can be separated
from each other on cer‐
tain vehicles:
♦ for the removal, carefully
press off the clamping
sleeve using a screwdriver
♦ for the installation, press
the clamping sleeve onto
the gearshift knob/collar
and lock in place
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
Parts
⇒ page 57
2 - Collar
❑ can be separated from
the gearshift knob on
certain vehicles
Parts
3 - Open warm-type clamp
❑ for securing the gear‐
shift knob to the gear‐
shift lever
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
4 - Noise insulation
❑ not fitted to all vehicles
❑ Catch pegs are positioned at different distances.
❑ therefore can only be inserted in one position.

OCTAVIA II 2004 ➤
1.4 Remove and install gearshift knob and

cover
– Lever the collar upwards and out of centre console surround
-arrows-.
Note
To do so, the release tool -T30098- can be used.
– Pull the collar upwards over the gearshift knob.
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Install
– Turn collar inside out.
– Insert gearshift knob and collar and compress new collar
clamp -arrow-.
When inserting the gearshift knob on the shift lever the gearshift
knob must lock into the round slot of the gearshift lever.

OCTAVIA II 2004 ➤
1.5 Summary of components - Gearshift mechanism (up to 10.06)
Note
Grease bearing and friction surfaces with grease -G 000 450 02- .
1 - Lock washer
⇒ page 59
2 - Bushing
3 - Spring
4 - Bushing
5 - 5 Nm
6 - Cover
7 - Damping
8 - Damping
9 - Bearing shell
10 - Shift lever guide
11 - Insulating washer
12 - Gasket
❑ between shift housing
and underbody
❑ self-adhesive
❑ stick onto shift housing
13 - Shift lever
14 - Shift housing
15 - Bushing
16 - Bearing bolt
17 - Guide bushing
18 - Spring
❑ installing ⇒ page 59
19 - Selector angle plate
20 - 5 Nm
21 - Gasket
❑ always replace ⇒ Electronic Catalogue of Original Parts
22 - Floor plate
❑ bend up tabs for removing
23 - Selector cable
❑ detaching and attaching at selector angle plate ⇒ page 59
24 - Shift cable
❑ remove from the shift lever guide pos. 10 ⇒ page 59

OCTAVIA II 2004 ➤
25 - Lock washer
26 - 8 Nm
❑ 4 pieces
27 - Bushing
❑ fits in one position only
28 - Lock washer
Detaching and attaching selector cable and shift cable

– Remove lock washer from shift cable -A- and selector cable
-B-.
To do so lift the tab with a screwdriver -arrow 1- and press off lock
washer -arrow 2-.
– Remove shift cable -A- from the support of the gearshift lever.
– Remove selector cable -B- from the support of the selector
angle plate.
Removing and installing lock washer

– To remove and install the circlip -arrow A- press bushing
-arrow B- with a screwdriver up to the stop in the direction of
the arrow -arrow C- and remove circlip.
Note
♦ Do not twist bushing when pressing down.

♦ Mounting slot in shift lever for lock washer must be visible.
♦ Release spring carefully.
Install pressure spring

– Insert the clamp -A- of the pressure spring from the top into
the guide -1-.
– Press the clamp -B- of the pressure spring downwards and
insert from the bottom into the guide.
Note
The illustration shows without the removed selector angle plate.

OCTAVIA II 2004 ➤
1.6 Summary of components - Gearshift mechanism (as of 11.06)
Note
1 - Floor plate
❑ bend up tabs for remov‐
ing
tronic Catalogue of
Original Parts
2 - Gasket
tronic Catalogue of
Original Parts
3 - Shift lever
❑ can be installed or re‐
moved with the shift lev‐
er guide pos. 15 moun‐
ted
4 - Insulating washer
❑ push up to the stop
-arrow- onto the shift
lever
5 - Lock washer
❑ do not damage cables
when removing
tronic Catalogue of
Original Parts
6 - Selector cable
❑ lever off from selector
angle plate
❑ press onto the selector
angle plate within the
shift mechanism
⇒ page 75
❑ Fitting position ⇒ page 54
❑ adjust ⇒ page 77
7 - Bush for selector cable
8 - Shift cable
❑ lever off from the shift lever guide
❑ press onto the shift lever guide within the shift mechanism
9 - Damping
10 - Bearing shell
❑ is damaged when removing.

OCTAVIA II 2004 ➤
11 - Bushing
12 - Lock washer
13 - Spring
14 - Bushing
15 - Shift lever guide
16 - Nut
❑ M8 = 25 Nm
❑ M6 = 8 Nm
❑ 4 pieces
17 - Gasket
❑ between shift housing and underbody
❑ self-adhesive
❑ stick onto shift housing
18 - Shift housing
❑ with pressure spring and selector angle
❑ Pressure spring and selector angle cannot be removed
Removing and installing lock washer

– Hold the gearshift lever -2-.
– Press the bushing -3- in the direction of the arrow.
– Remove lock washer -1-.
Removing and installing damping -arrow-

– Press the pressure spring leg -A- to the left until it is located
next to the damping -arrow-.
– Press the shift lever to the lift and pull off the damping.
• After installing the damping, the pressure spring legs -A- and
-B- must rest on the damping -arrow-.

OCTAVIA II 2004 ➤
1.7 Disassembling and assembling the

gearshift mechanism (as of 11.06)
♦ Insert base -T10083-
♦ Grease -G 000 450 02-
1.7.1 Dismantling
– Removing shift mechanism ⇒ page 71 .
– Bend up the tabs -arrows- of the floor plate for shift mechanism
with a screwdriver and remove the floor plate; (the tabs in the
front area of the floor plate are not shown in the illustration).
– Remove gasket from shift housing.
– Remove shift cable and selector cable from the shift housing
⇒ page 60 .
– Lift the upper leg -A- of the pressure spring over the tabs of
the selector angle.
– Use a screwdriver to press the catches -arrows- of the bearing
shell in direction of the bearing ball for the shift lever guide; if
necessary break off the catches -arrows-.
– Lever bearing shell -A- with shift lever guide and shift lever
-B- out of the shift housing.
– Then press the bearing shell off the bearing ball for the shift
lever guide and remove.

OCTAVIA II 2004 ➤
• During further work procedure observe the guides -A-.

• The guides -A- must not break off.
– Lever the lower leg of the pressure spring up to the stop onto
the shoulder at the selector angle plate -direction of arrow 1-.
– Now pull up the shift lever guide as far as the stop and pull the
ball stud out of the selector angle plate -direction of arrow 2-.
– Then turn the shift lever guide in -direction of arrow 1-.

• The stud -arrow 2- must be located in the recess of the shift
housing.
– Afterwards, swivel out the shift lever guide with shift lever in
-direction of arrow 3-.
1.7.2 Assembling together
Caution
The lower leg of the pressure spring ( ⇒ page 63 ) can jump off
uncontrolled from the shoulder of the selector angle during fur‐
ther handling.
– Thus carefully press down the lower leg from the shoulder of
the selector angle plate.
The legs of the pressure spring tighten “crosswise” with a loud
noise
– To slacken, turn around the legs of the pressure spring -A- and
-B- towards the right.
• The legs -A- and -B- must point in the opposite direction
(shown here for inserted shift lever guide).

OCTAVIA II 2004 ➤
– Insert shift lever guide with shift lever into the shift housing.
• The stud -arrow 1- is still located in the recess of the shift
housing.
– Turn shift lever guide in -direction of arrow 2-, until the ball stud
-A- is above the recess of the shift housing.
– Position shift housing with shift lever guide into the larger re‐
cess -arrow- of the Insert base -T10083- .
Note
If necessary, first of all remove the shift lever so that the shift
housing with shift lever guide can be inserted in the insert base .
• The shift lever guide must protrude out of the shift housing as
far as the stop.
– Insert the leg -A- of the pressure spring from the top into the
guide.
– Pull leg -B- of pressure spring downwards and insert the leg
-B- next to the guide (in direction of the spherical head).
Note
To provide a clearer illustration, only the selector angle plate is

partially illustrated.
– Carefully remove shift housing with shift lever guide from the
insert base -T10083- .
– Move selector angle plate up to stop to the rear (opposite the

location holes for shift and selector cable)
– Grease the ball stud with grease -G 000 450 02- .
– Press the ball stud into the selector angle plate -arrow 2-.
• The guides -A- and the tabs -B- must not be damaged.

OCTAVIA II 2004 ➤
– Position shift housing with shift lever guide into the larger re‐
cess -arrow- of the Insert base -T10083- .
• The shift lever guide must protrude out of the shift housing as
far as the stop.
– Lift the upper leg -A- of the pressure spring over the stud of
the selector angle plate.
• Use a new bearing shell -B-.
– Grease the bearing shell and the bearing ball of the shift lever
guide with grease -G 000 450 02- .
– Press the bearing shell up to stop onto the bearing ball of the
shift lever guide.
– Remove shift housing from the insert base -T10083- .
– Press the bearing shell into the shift housing -arrows-.
• All catch pegs must click audibly.
– Insert the lower leg -C- of the pressure spring into the guide.
– Lift the upper leg -A- of the pressure spring over the stud of
the selector angle plate into the guide.
Note
If the shift lever was removed, install the shift lever ⇒ page 60 .
– Mount shift cable, selector cable and floor plate ⇒ page 75 .

– Installing shift mechanism ⇒ page 71 .

OCTAVIA II 2004 ➤
1.8 Summary of components - Control cables
Note
1 - Shift cable
❑ connect with cable lock
Pos. 18
⇒ page 75
⇒ page 54
❑ as of 11.06 modified at‐
tachment to the gear‐
shift lever within the shift
mechanism ⇒ page 60
❑ after installing set shift
mechanism
⇒ page 77
2 - Selector cable
❑ connect with cable lock
Pos. 11
⇒ page 75
⇒ page 54
❑ as of 11.06 modified at‐
tachment to the selector
angle plate within the
shift mechanism
⇒ page 60
mechanism
⇒ page 77
3 - Lock washer
tronic Catalogue of
Original Parts
❑ no longer applicable
⇒ page 60 for shift
mechanisms as of 11.06
4 - Lock washer
❑ do not damage cables when removing
5 - Shift housing
6 - 20 Nm
❑ 2 pieces
❑ for cable support
7 - Cable support
❑ made out of plastic or metal

OCTAVIA II 2004 ➤
8 - Grommet
❑ Mounting of cable support to gearbox
9 - Spacer
10 - 20 Nm
❑ for cable support
11 - Cable lock
❑ for selector cable at relay lever
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different
❑ after installing set shift mechanism ⇒ page 77
❑ as of 06.07 it is fitted together with plastic relay lever ⇒ page 70
❑ remove from plastic relay lever ⇒ page 70
❑ press onto plastic relay lever ⇒ page 70
❑ Assignment ⇒ page 68
12 - Reversing lever
❑ made out of plastic or metal
❑ Metal relay lever is located in the bushings pos. 13 and secured with a lock washer pos. 14
❑ as of 06.07 plastic relay lever ⇒ page 70
❑ remove and install plastic relay lever together with cable lock ⇒ page 70
❑ Bushings pos. 13 and lock washer pos. 14 are not required for plastic relay lever
13 - Bushing
❑ is not required for plastic relay lever
14 - Lock washer
15 - Sliding shoe
16 - Gearshift lever
❑ with balancing weight
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft
❑ as of 06.06 smaller diameter of the mounting pin for the cable lock ⇒ page 68
17 - 23 Nm
18 - Cable lock
❑ for shift cable at gearbox shift lever
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different

OCTAVIA II 2004 ➤
Assignment of the cable locks

The holes in the cable locks have different diameters.
Cable lock for: Dimension “a”
1. - Shift cable at gearbox shift lever as of 06.06 8.5 mm
2. - Shift cable at gearbox shift lever up to 05.06 10 mm
2. - Selector cable at metal relay lever 8 mm
2. - Selector cable at plastic relay lever 10 mm
⇒ page 70
As of 06.06 smaller diameter of the mounting pin for the cable lock
of the shift cable
Mounting pin for the cable lock of the shift cable Dimension “a”
to 05.06 10 mm
from 06.06 8.5 mm
Fitting location of gearbox shift lever/relay lever

1 - Gearbox shift lever with balancing weight
2 - Relay lever is inserted over the sliding shoe -arrow- into the
sliding rail of the gearbox shift lever

OCTAVIA II 2004 ➤
1.8.1 Replace cable lock

– Pull forward the locking mechanism at selector cable and at
shift cable as far as the stop -direction of arrow 1-, then lock
by turning to the left -direction of arrow 2-.
– Remove circlip -3- for shift cable from gearbox shift lever -1-.
– Pull off shift cable from the stud -arrow-.
Metal relay lever
– Remove circlip -4- for the selector cable from relay lever -2-.
– Pull selector cable off the stud.
Plastic relay lever
– Remove relay lever together with cable lock ⇒ page 70 .
– Lever off cable lock from relay lever ⇒ page 70 .
Continued for all gearshift mechanisms
– Apply a small quantity of grease -G 000 450 02- onto the studs
-arrows- of the gearbox shift lever -1- and of the relay lever
-2-.
– Replace circlip -3- and circlip -4- for the metal relay lever after
each disassembly.
– Secure the shift cable with the lock washer -3- and secure the
selector cable with the lock washer -4- for metal relay lever.
Note
If a plastic relay lever is installed, it must be mounted together

with the cable lock ⇒ page 70 .
Setting the shift mechanism ⇒ page 77 .

OCTAVIA II 2004 ➤
1.9 Plastic relay lever
1.9.1 Removing and installing the plastic relay

lever
– Pull forward the locking mechanism as far as the stop in
-direction of arrow 1-, then lock by turning to the left in
• In order to avoid damage to the selector cable, the cable lock
must be separated from the selector cable before removal.
• Gearbox shift lever is located in the neutral position.
The relay lever is secured with a catch -arrow 1- in the cover

– Carefully press down the catch -arrow 1- up to the stop.
– Afterwards move the relay lever -A- back and forward in its
bearing point (direction of operation) -arrow 2-. To do so, care‐
fully pull out the relay lever -A- together with the cable lock
-B- in -direction of arrow 3-.
• Only remove the cable lock -B- on removed relay lever
⇒ page 71 .
Note
♦ To install, grease bearing points and friction surfaces with

grease -G 000 450 02- .
♦ Press cable lock onto the relay lever ⇒ page 71 .
♦ Insert relay lever together with cable lock.
• The catch -arrow 1- secures the relay lever.

• The cable lock -B- must be located behind the catch
-arrow 4-.

OCTAVIA II 2004 ➤
The relay lever is secured with a clip -A- in the cover

– Detach the clip -A- and remove the relay lever -C- together
with the cable lock -D-.
Note
♦ To install, grease bearing points and friction surfaces with

grease -G 000 450 02- .
♦ Press cable lock onto the relay lever ⇒ page 71 .
♦ Insert relay lever together with cable lock.
♦ Secure the relay lever with a clip -A-.
1.9.2 Removing and installing the cable lock

for selector cable from the plastic relay
lever
Lever off cable lock for selector cable from plastic relay lever
• The relay lever is removed.
– Position a cross-head screwdriver -A- between the bush -B-
and the relay lever.
Press on cable lock

• The relay lever is removed.
• The cable lock must only be pressed onto the bush -arrow-.
• The cable lock must move freely on the relay lever.
• It must be located behind the catch ⇒ page 70 .
1.10 Removing and installing shift mecha‐

nism
1.10.1 Removing

OCTAVIA II 2004 ➤
♦ Grease -G 000 450 02-
Note
If the battery earth strap is disconnected and connected, carry out

additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 .

-arrows-.
Note
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
– If present, detach the noise insulation.
– Remove the ashtray ⇒ Body Work ⇒ Rep. Gr. 68 .
– Unscrew nuts -arrows- attaching the shift housing.

Rep. Gr. 24 .

OCTAVIA II 2004 ➤
– Remove circlip -3- for shift cable from gearbox shift lever -1-.
– Pull off shift cable from the stud -arrow-.
Metal relay lever
– Remove circlip -4- for the selector cable from relay lever -2-.
– Pull off selector cable from the stud -arrow-.
Plastic relay lever
In order to avoid damage to the selector cable, the cable lock must
be separated from the selector cable before removal.
– Remove the plastic relay lever together with the cable lock
⇒ page 70 .
– Disconnect the Bowden cable support from gearbox

-arrows-.
– If present, remove the sound dampening system ⇒ Body work
⇒ Rep. Gr. 50 .
– Remove underbody cover on right and left -arrows-.

OCTAVIA II 2004 ➤
– Detach tunnel bridges -1- below the exhaust system ⇒ Engine

⇒ Rep. Gr. 26 .
– Separate exhaust system at the clamping sleeve -arrows- and
remove from the assembly carrier ⇒ Engine ⇒ Rep. Gr. 26 .
– Support the front exhaust pipe.
Note
The decoupling elements in the exhaust pipe should not be bent

by more than 10° - risk of damage.
– Unhook the rear silencer -2- from the retaining straps.

For vehicles with four-wheel drive
– If necessary remove pre-exhaust pipe.
– Remove the rear part of the exhaust gas system ⇒ Engine ⇒
Rep. Gr. 26 .
– Unscrew heat shield -2- for propshaft.

– Remove propshaft ⇒ page 223 .
For all vehicles
– Remove the heat shield below the shift housing.
– Swivel shift housing down and remove with control cables.
1.10.2 Install
following points:
The holes in the cable locks have different diameters.
Assignment of the cable locks ⇒ page 68 .
– Apply a small quantity of grease -G 000 450 02- onto the studs
-arrows- of the gearbox shift lever -1- and of the relay lever
-2-.
– Replace circlips -3- and circlip -4- for the metal relay lever after
each disassembly.
– Secure the shift cable with the lock washer -3- and secure the
selector cable (for metal relay lever) with the lock washer -4-.
Cable lock with plastic relay lever
– The relay lever and the cable lock must be mounted together
⇒ page 70 .
– Insert the selector cable into the cable lock.
– Align shift housing parallel to vehicle body.
• The distance to the vehicle body must be the same on both
sides.
– Install the ashtray ⇒ Body Work ⇒ Rep. Gr. 68 .

OCTAVIA II 2004 ➤
– Replace clamp -arrow-.

For vehicles with four-wheel drive
– Install propshaft ⇒ page 223 .
For all vehicles
– Assemble exhaust system free of stress and attach tunnel
bridges ⇒ Engine ⇒ Rep. Gr. 26 .
– Install underbody cover on right and left ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Setting the shift mechanism ⇒ page 77 .
Gr. 24 .
Note

27 .
– Connect earth strap of battery while paying attention to the

notes in the ⇒ Electrical System ⇒ Rep. Gr. 27 .
Tightening torques
Component Nm
Shift housing to body ⇒ page 58 and ⇒ page 60
Cable support to gearbox ⇒ page 66
Underbody cover ⇒ Body Work ⇒ Rep. Gr. 50
1.11 Removing and installing shift cable and

selector cable
1.11.1 Removing
– Removing shift mechanism ⇒ page 71 .
– Bend up tabs -arrows- of cover for the shift mechanism using
a screwdriver and remove cover.
– Remove gasket ring.
Vehicles up to 10.06

OCTAVIA II 2004 ➤
– Remove circlips -1,2,3,4- and remove shift cable and selector

cable from shift housing.
Vehicles as of 11.06
– Remove lock washers -2 and 3- (lock washers -1 and 4- are

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

– Remove the cable support from the cables.
1.11.2 Install
following points:

OCTAVIA II 2004 ➤
Vehicles up to 10.06
– Attach shift cable and selector cable to shift housing with cir‐
clips -2 and 3-.
– Fasten shift cable and selector cable onto shift lever and se‐
lector lever into shift housing with lock washers -1 and 4-.
Vehicles as of 11.06
– Attach shift cable and selector cable to shift housing with cir‐
clips -2 and 3-.
– Press shift cable and selector cable onto shift lever and se‐
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
– Install gasket and attach cover for shift mechanism by press‐

ing on the tabs -arrows-.
– Installing shift mechanism ⇒ page 71 .
– Setting the shift mechanism ⇒ page 77 .
1.12 Setting the shift mechanism

♦ Rig pin -T10027A-
Note
The following are required for correct setting of the shift mecha‐
nism:
• Gearbox, clutch and clutch control in perfect condition

• Shift mechanism operates freely
• Control element and transmission elements of the shift mech‐
anism are in perfect condition
• Gearbox in Neutral
Rep. Gr. 24 .

OCTAVIA II 2004 ➤
– Pull forward the locking mechanism at shift cable and at se‐

lector cable as far as the stop in -direction of arrow 1-, then
lock by turning to the left in -direction of arrow 2-.
Fix the gearshift shaft as follows:

– Press down the gearshift shaft in -direction of arrow 1-.
– When pressing down the gearshift turn the angle lever -A- in
-direction of arrow 3- upwards and while doing so press it si‐
multaneously in -direction of arrow 2-, until it locks into the
gearshift shaft.

-arrows-.
Note
– If present, remove the noise insulation.

Now fix the gearshift lever as follows:
– Engage Neutral on gearshift lever.
– Insert rig pin -T10027A- through hole -A- into hole -B-.

OCTAVIA II 2004 ➤
– Turn locking mechanism at shift cable and at selector cable to

the right up to the stop in -direction of arrow 1-.
The spring pushes the locking mechanism into the initial position
– Turn angle lever -A- back to the initial position

-in direction of arrow 2-.
The angle lever -A- must be pressed out of the gearbox in
The gearshift shaft must now move in the

-direction of the arrow-.
– Pull rig pin -T10027A- out of hole -A- and -B-.

– If present, install the noise insulation.
– Press collar into the cover.
Gr. 24 .

OCTAVIA II 2004 ➤
1.12.1 Operation
• Shift lever must be positioned in Neutral in the selector lever
gate of the 3rd/4th gear.
– Actuate clutch pedal.
– Shift through all gears several times. Pay particular attention
to proper operation of the reverse gear lock.
If a gear catches when engaged again, set the shift mechanism
once again ⇒ page 77 .

OCTAVIA II 2004 ➤
2 Removing and installing the gearbox
2.1 Removing gearbox - Front-wheel-drive

♦ Adapter -MP3-419/40 (VW 771/40)-
♦ Gearbox attachment device -MP3-478 (3336)-
♦ Hose clamps -MP7-602 (3094)-
♦ Supporting device -T30099-
♦ Washer -T30099/1-
♦ Gearbox mount -3282-
♦ Adjusting plate -3282/33-
♦ Engine and gearbox jack e.g. -V.A.G 1383A-
– Remove engine cover ⇒ engine ⇒ Rep. Gr. 10 .
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ After the battery earth strap is disconnected and connected,
carry out additional operations ⇒ Electrical System ⇒ Rep.
Gr. 27 .

Rep. Gr. 24 .
Gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Remove lock washer -3- for shift cable from gearbox shift lever
-1- and pull off the shift cable from the stud -arrow-.
Metal relay lever
– Remove lock washer -4- for selector cable from relay lever
-2- and pull off the selector cable from the stud -arrow-.
2. Removing and installing the gearbox 81

OCTAVIA II 2004 ➤
Plastic relay lever

Continued for all vehicles:
– Disconnect cable support from gearbox -arrows-, lay aside

and tie up.
A tube-hose line or a plastic line is fitted between the master cyl‐
inder and the bleeder.
Note

– If a plastic line is fitted, then the return hose must be removed

at the master cylinder and closed in a suitable manner (do not
use hose clamp -MP7–602- ).
– If a tube-hose line is fitted, pinch off the hose for the tube-hose
line -A- to the master cylinder with the hose clamp -MP7-602
(3094)- (do not use the hose clamp -MP7–602- for the plastic
line -A-).
– Pull out retaining clip -arrow- for tube-hose line and/or plastic
line up to the stop.
– Pull out the tube-hose line and/or plastic line from the bleeder/
slave cylinder and close in a suitable manner.
Caution
After removing the tube-hose line, do not operate the clutch

pedal.

OCTAVIA II 2004 ➤
– Remove earth strap -1- from top starter.

– Disconnect plug -2- of the reversing light switch -F4- .
– Disconnect connector and cables from the starter.
– Remove engine/gearbox connecting screws at the top.
– Remove fixing screw for starter at the top.
– If hose and cable connections are located in the area of the
lifting eye of the engine for the supporting device -T30099- ,
these must now be removed.
– Fit supporting device -T30099- .

– Take up the weight of the engine/gearbox unit at the spindle.
– Loosen the wheel bolts on front left and front right.
– Raise vehicle ⇒ Maintenance ; .
– Remove wheels at the front.
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 and
lower part of the front left wheelhouse liner ⇒ Body Work ⇒
Rep. Gr. 66 .
– Unscrew bracket from starter.
– Remove the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Disconnect plug connection -2- at the charge pressure sender

-G31- .
– Unscrew bolt -4-.
– Remove the air guide pipe between the charge air cooler and
the intake manifold, to do so slightly raise the retaining clips
-1- and -3- ⇒ Engine ⇒ Rep. Gr. 21 .
– Remove support (if present) -1- for exhaust system from gear‐
box -arrow- and front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 .
– Separate exhaust system at the clamping sleeve and remove
bracket for the exhaust system from the assembly carrier ⇒
Engine ⇒ Rep. Gr. 26 .
– Tie up pre-exhaust pipe.
Note


OCTAVIA II 2004 ➤
– Remove pendulum support from gearbox, to do so release the

bolts -arrow B- and -arrow C-.
– Remove the left drive shaft from the flange shaft of the gearbox
⇒ Chassis ⇒ Rep. Gr. 40 and tie up as far as possible (do
not damage the surface protection).
– Disconnect plug -B- from oil level and oil temperature sender
-G266- .
For vehicles with intermediate shaft:
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Remove right intermediate shaft -C- from bracket -D-
-arrows- and pull off from the rigid shaft of the gearbox.
For vehicles without intermediate shaft:
– Only remove right drive shaft from the flange shaft -A- of the
gearbox.
– Remove screen cap for drive shaft (if present) from the engine
-arrows-
– Secure drive shaft (e.g. with wire, cord).

OCTAVIA II 2004 ➤
– Disconnect the plug connection on the front left vehicle level

sensor -G78- (if present).
– Unscrew nut -2-.
– Release screw -1- and remove the sender.
– Fix the assembly carrier before removing ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Remove the assembly carrier with console without steering
gear, left track control arm and coupling rod ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Unscrew the screws -arrows- of the left unit mounting -2- from
the console -1-.
– Lower the gearbox to the dimension -a- approx. 60 mm by

adjusting the spindle.
– Unscrew the fixing screws -arrows- for the console -1-.

– Remove console -1- from gearbox.

OCTAVIA II 2004 ➤
Metal relay lever

– Detach circlip -arrow- from the relay lever -1- and remove relay
lever.
Plastic relay lever
The relay lever is secured with a clip -arrow 1- in the cover

– Remove the clip -arrow 1- and the relay lever together with the
cable lock -arrow 2-.

– Move back and forward reversing lever -A- in its position
-arrow 2-. To do so carefully pull out in -direction of arrow 3-
with the cable lock -B-.
Note
To install, grease bearing points and friction surfaces with grease

-G 000 450 02- .

– Remove the gearshift lever from the gearshift shaft.
– Remove engine/gearbox connecting screws at the bottom and
screw (M8 x 30) for the bracket of the coolant pipe to turbo‐
charger (if this wiring is available).
Align gearbox mount -3282 - for removal of gearbox “02Q” with
adjusting plate -3282/33- .
– Insert gearbox mount -3282 - into engine/gearbox jack , e.g. -
V.A.G 1383A- .
– Align arms of the gearbox mount to match the holes in the
adjusting plate .

OCTAVIA II 2004 ➤
– Screw in mounting elements -A-, as shown on the adjusting

plate .
– Instead of the mounting element -C- screw in the bolt -3282/29
-.
– Position the engine and gearbox jack e.g. -V.A.G 1383A- be‐
low the vehicle; the arrow -B- on the adjusting plate points in
the direction of travel/vehicle.
– Align the adjusting plate parallel to the gearbox.
– Secure adapter -MP3-419/40- in the threaded bore of the

gearbox housing as shown.
– Then screw in the bolt -3282/29- into the hole for the fixing
screw of the pendulum support on the gearbox.
– Secure the gearbox on the gearbox mount -3282- using screw
(M10 x 20) -A-.
While doing so the drift -B- should close at the bottom flush with
the guide of the gearbox mount -3282- -arrow-.
– Remove engine/gearbox -C- connecting screw.
For vehicles with auxiliary heating
– Unscrew screw -1- and carefully press off the pipe -2- of the
auxiliary heating from the engine -in direction of arrow-.
– Remove small cover plate -A- for flywheel.

– Unscrew engine/gearbox connecting screw -arrow-.
– Press gearbox from engine (dowel sleeves).

OCTAVIA II 2004 ➤
– Turn the gearbox in the area of the differential gear via the
spindle -1- of the gearbox mount -3282- upwards.
– Position the gearbox via the spindle -2- of the gearbox mount
-3282- inclined to the left.
– Then guide the right flange shaft of the gearbox past the fly‐
wheel, while doing so observe the frame side rail -arrow-.
– Carefully lower the gearbox.
Note
Observe all lines when lowering the gearbox.
2.2 Removing gearbox - Four-wheel drive

♦ Adapter -MP3-419/40 (VW 771/40)-
♦ Gearbox attachment device -MP3-478 (3336)-
♦ Hose clamps -MP7-602 (3094)-
♦ Supporting device -T30099-
♦ Gearbox mount -3282-
♦ Adjusting plate -3282/33-
– Remove engine cover ⇒ engine ⇒ Rep. Gr. 10 .
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
Gr. 27 .

– Remove air filter ⇒ Engine ⇒ Rep. Gr. 23 .
Gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .

OCTAVIA II 2004 ➤
Metal relay lever
Plastic relay lever


and tie up.
– If present, remove the ventilation pipe from the angle gearbox

-arrow-.
A tube-hose line or a plastic line is fitted between the master cyl‐
inder and the bleeder.
Note


OCTAVIA II 2004 ➤
– If a plastic line is fitted, then the return hose must be removed

at the master cylinder and closed in a suitable manner (do not
use hose clamp -MP7–602- ).
– If a tube-hose line is fitted, pinch off the hose for the tube-hose
line -A- to the master cylinder with the hose clamp -MP7-602
(3094)- (do not use the hose clamp -MP7–602- for the plastic
line -A-).
– Pull out retaining clip -arrow- for tube-hose line and/or plastic
line up to the stop.
– Pull out the tube-hose line and/or plastic line from the bleeder/
slave cylinder and close in a suitable manner.
Caution
After removing the tube-hose line, do not operate the clutch

pedal.
– Remove earth strap -1- from top starter.

– Disconnect plug -2- of the reversing light switch -F4- .
– Disconnect connector and cables from the starter.
– Remove engine/gearbox connecting screws at the top.
– Remove fixing screw for starter at the top.
– If hose and cable connections are located in the area of the
lifting eye of the engine for the supporting device -T30099- ,
these must now be removed.
– Fit supporting device -T30099- .

– Take up the weight of the engine/gearbox unit at the spindle.
– Raise vehicle ⇒ Maintenance ; Octavia II .
lower part of the front left wheelhouse liner ⇒ Body Work ⇒
Rep. Gr. 66 .
– Unscrew bracket from starter.
– Remove the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .

OCTAVIA II 2004 ➤
– Disconnect plug connection -2- at the charge pressure sender

-G31- .
– Unscrew bolt -4-.
– Remove the air guide pipe between the charge air cooler and
the intake manifold, to do so slightly raise the retaining clips
-1- and -3- ⇒ Engine ⇒ Rep. Gr. 21 .
– Disconnect plug connection -1-.

– Screw out screws -arrows- and take out fan shroud down‐
wards.
– Remove all supports for exhaust gas system from gearbox and
from pre-exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 .
Note

– If present, remove screen cap for drive shaft -arrows-.
– Mark the position of the propshaft with flexible disk to the

flange of the angle gearbox.
– Unscrew propshaft with flexible disk from flange of angle gear‐
box -arrows-.

OCTAVIA II 2004 ➤

Note
After removing the pendulum support from the gearbox, the en‐
gine/gearbox unit swivels slightly towards the front (direction
front). When removing and installing make sure that the gasket
ring -arrow- in the flange of the propshaft is not damaged.
– Push engine/gearbox unit forwards and take propshaft out of

angle gearbox.
– Raise propshaft and tie up.
– Disconnect plug -1- for oil level and oil temperature sender -
G266- .

sensor -G78- .
Gr. 40 .
– Remove the assembly carrier with console without steering
gear, left track control arm and coupling rod ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Remove left and right drive shafts from the flange shafts of the
gearbox ⇒ Chassis ⇒ Rep. Gr. 40 and tie up as far as possible
(do not damage the surface protection).

OCTAVIA II 2004 ➤
For vehicles without particle filter:

– Remove oil line for exhaust turbocharger -A- at engine.
– Remove support between engine and angle gearbox
-arrows-.
For vehicles with particle filter:

– Remove particle filter with bracket for particle filter ⇒ Engine
⇒ Rep. Gr. 26 .
– Release screws for support between engine and angle gear‐
box -arrows 1, 2- and -3-.
Note
The support between engine and angle gearbox can only be re‐
moved if the gearbox is removed from the engine.

– For these vehicles the angle gearbox -1- must be removed
⇒ page 101 .
Note
♦ Otherwise the pipe -2- of the auxiliary heating is damaged.

♦ The engine/gearbox connecting screw -arrow- can be re‐
moved from the cylinder block only after removing the pipe
-2- ⇒ page 96 .
– Unscrew the screws -arrows- of the left unit mounting -2- from
the console -1-.

OCTAVIA II 2004 ➤
– Lower the gearbox to the dimension -a- approx. 60 mm by

adjusting the spindle.
– Unscrew the fixing screws -arrows- for the console -1-.

– Remove console -1- from gearbox.
Metal relay lever

– Detach circlip -arrow- from the relay lever -1- and remove relay
lever.
Plastic relay lever
The relay lever is secured with a clip -arrow 1- in the cover

– Remove the clip -arrow 1- and the relay lever together with the
cable lock -arrow 2-.

OCTAVIA II 2004 ➤

– Move back and forward reversing lever -A- in its position
-arrow 2-. To do so carefully pull out in -direction of arrow 3-
with the cable lock -B-.
Note
To install, grease bearing points and friction surfaces with grease

-G 000 450 02- .

– Remove the gearshift lever from the gearshift shaft.
– Remove engine/gearbox connecting screws below.
Align gearbox mount -3282 - for removal of gearbox “02Q” with
adjusting plate -3282/33- .
– Insert gearbox mount -3282 - into engine/gearbox jack , e.g. -
V.A.G 1383A- .
– Align arms of the gearbox mount to match the holes in the
adjusting plate .
– Screw in mounting elements -A-, as shown on the adjusting

plate .
– Instead of the mounting element -C- screw in the bolt -3282/29
-.
low the vehicle; the arrow -B- on the adjusting plate points in
the direction of travel/vehicle.
– Align the adjusting plate parallel to the gearbox.
– Secure adapter -MP3-419/40- in the threaded bore of the

gearbox housing as shown.
– Then screw in the bolt -3282/29- into the hole for the fixing
screw of the pendulum support on the gearbox.
– Secure the gearbox on the gearbox mount -3282- using screw
(M10 x 20) -A-.
While doing so the drift -B- should close at the bottom flush with
the guide of the gearbox mount -3282- -arrow-.
– Remove engine/gearbox -C- connecting screw.

OCTAVIA II 2004 ➤
– Unscrew screw -1- and carefully press off the pipe -2- of the
auxiliary heating from the engine -in direction of arrow-.
– Remove small cover plate -A- for flywheel.
Note
To provide a clearer illustration, the figure of the front drive is

used.
– Unscrew engine/gearbox connecting screw -arrow-.

– Press gearbox from engine (dowel sleeves).

– Remove support -A- between engine and angle gearbox.
– Turn the gearbox in the area of the differential gear via the
spindle -1- of the gearbox mount -3282- upwards.
– Position the gearbox via the spindle -2- of the gearbox mount
-3282- inclined to the left.
– Then guide the gearbox/angle gearbox past the flywheel,
while doing so observe the frame side rail -arrow-.
– Carefully lower the gearbox.
Note
Observe all lines when lowering the gearbox.

OCTAVIA II 2004 ➤
2.3 Transporting the gearbox

– Screw down gearbox suspension device -MP3-478- onto
clutch housing.
– Adjust supporting arm at slide with locking pin -arrow-.

Number of visible holes:
♦ on front drive = 6
♦ on four-wheel drive = 9
– Raise gearbox with workshop crane and gearbox suspension
device -MP3-478- .
– Place down gearbox, e.g. in a transport container.
2.4 Installing the gearbox

The installation of the gearbox occurs in reverse order. Observe
the stress-free assembly bracket in the vehicle ⇒ Engine ⇒ Rep.
Gr. 10 .
For vehicles with particle filter and four-wheel drive:
Fit support between engine and angle gearbox -A- onto the angle
gearbox before flange mounting the gearbox.

OCTAVIA II 2004 ➤
Note
♦ Clean splines of drive shaft and apply a thin film of grease for
plug serration of clutch disc -G 000 100- .
♦ Always replace the self-locking nuts and screws.
♦ If the gearbox is inserted, ensure the intermediate plate be‐
tween the engine and gearbox is correctly installed.
♦ Check whether the dowel sleeves for centering the gearbox
are present in the cylinder block, insert missing sleeves. If the
sleeves are not provided, complications while shifting as well
as problems with the clutch might occur and gearbox noises
could arise.
♦ As of gearbox manufacturing date 28 05 7 threaded inserts
are located in the bolt-holes for the pendulum support (e.g.
“HeliCoil”).
♦ Distinguishing feature: Shoulder at first thread turn -arrow-.
♦ Pay attention to the corresponding fixing screws and the tight‐
ening torque for the pendulum support ⇒ Engine ⇒ Rep. Gr.
10 .
♦ Installing starter and cables ⇒ Electrical System ⇒ Rep. Gr.
27 .
♦ Pay attention to the tightening sequence of the fixing screws
for the support between engine and angle gearbox
⇒ page 108 .
♦ Install water box cover ⇒ Body Work ⇒ Rep. Gr. 66 .
♦ Install air filter ⇒ Engine ⇒ Rep. Gr. 23 or ⇒ Engine ⇒ Rep.
Gr. 24 .
♦ Bleed the clutch control ⇒ page 36 .
♦ Attach the shift mechanism to the gearbox ⇒ page 71 .
♦ Setting the shift mechanism ⇒ page 77 .
♦ Inspect the gear oil level in the gearbox ⇒ page 100 .
♦ Check gear oil level in the angle gearbox ⇒ page 109 .
♦ If the front left vehicle level sensor -G78- was removed, then
the headlight beam setting must be checked ⇒ Electrical Sys‐
tem ⇒ Rep. Gr. 94 .
♦ Install noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 and lower
part of the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
♦ Install front wheels ⇒ Chassis ⇒ Rep. Gr. 44 .
Gr. 27 .

OCTAVIA II 2004 ➤
2.4.1 Tightening torques

Gearbox to engine (flange fig. gearbox)
Pos. Screw Pieces Nm
11) M 12 x 55 2 80
21) 2) M 12 x 165 2 80
3 M 10 x 105 1 40
4 M 10 x 50 2 40
53) M 12 x 70 1 80
A Dowel sleeves 2
1) Screw with threaded pin M8
2) additional starter to gearbox
3)screwed in from the engine side
– Replace screws -1- and -3 to 5- ⇒ Electronic Catalogue of
Original Parts .
Component Tightening torque

Gearbox console to gearbox1) 60 Nm + 90°
Gearbox console to gearbox 60 Nm + 90°
mount1)
Cover plate for flywheel 10 Nm
Screen cap of drive shaft to engine 35 Nm
Screen cap of drive shaft to angle 20 Nm
gearbox
Support between engine and angle ⇒ page 108
gearbox
Gearbox shift lever to gearshift shaft ⇒ page 66
Propshaft to angle gearbox ⇒ page 233
Pendulum support to gearbox ⇒ Engine ⇒ Rep. Gr. 10
Support for particle filter ⇒ Engine ⇒ Rep. Gr. 26
Exhaust pipe with catalytic converter ⇒ Engine ⇒ Rep. Gr. 26
Supports for exhaust manifold ⇒ Engine ⇒ Rep. Gr. 26
Bracket for electric cables ⇒ Electrical System ⇒ Rep. Gr. 27
Drive shaft to flange shaft ⇒ Chassis ⇒ Rep. Gr. 40
Coupling rod ⇒ Chassis ⇒ Rep. Gr. 40
Assembly carrier with consoles and ⇒ Chassis ⇒ Rep. Gr. 40
track control arms
Front left side vehicle level sensor - ⇒ Chassis ⇒ Rep. Gr. 40
G78-
Wheel bolts ⇒ Chassis ⇒ Rep. Gr. 44
1)Always replace screws ⇒ Electronic Catalogue of Original
Parts .

OCTAVIA II 2004 ➤
3 Inspect gear oil

♦ Socket wrench insert -T30023 (3357)-
Gearbox oil specification ⇒ Electronic Catalogue of Original
Parts .
– Remove the sound dampening system of engine/gearbox ⇒
Body Work ⇒ Rep. Gr. 50 .
– 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.
– Screw in screw -arrow- using a new sealing ring.
– Tighten screws -arrow- to tightening torque ⇒ page 145 .
If re-filling, do the following:
– Unscrew plug -arrow-.
– Pour in gear oil up to lower edge of filler hole.
– Screw in screw -arrow- using a new sealing ring.
– Tighten screws -arrow- to tightening torque ⇒ page 145 .
– Install the noise insulation below the engine/gearbox ⇒ Body
Work ⇒ Rep. Gr. 50 .
Different versions of oil filler plug and oil drain plug.

I - Oil filler plug and oil drain plug with internal serration
II - Oil filler plug and oil drain plug with Allan key

OCTAVIA II 2004 ➤
4 Removing and installing angle gear‐

box
♦ Socket insert -T10107A-
4.1 Remove angle gearbox

First check if a ventilation pipe -arrow- is mounted at the angle
gearbox.
Rep. Gr. 24 .
To remove the ventilation pipe, the shift mechanism must be re‐
moved from the gearbox:
Metal relay lever
Plastic relay lever

4. Removing and installing angle gearbox 101

OCTAVIA II 2004 ➤

and tie up.
– If present, remove the ventilation pipe from the angle gearbox

-arrow-.
front right wheelhouse liner ⇒ Body Work ⇒ Rep. Gr. 66 .
– Remove all supports for exhaust gas system from gearbox and
from pre-exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 .

bracket for the exhaust system from the assembly carrier
-arrows- ⇒ Engine ⇒ Rep. Gr. 26 .
Note

– If present, remove heat shield for drive shaft -arrows-.

OCTAVIA II 2004 ➤
– Disconnect plug -1- from oil level and oil temperature sender
-G266- .
– Mark the position of the propshaft with flexible disk to the

flange of the angle gearbox.
– Unscrew propshaft with flexible disk from flange of angle gear‐
box -arrows-.

Note
After removing the pendulum support from the gearbox, the en‐
gine/gearbox unit swivels slightly towards the front (direction
front). When removing and installing make sure that the gasket
ring -arrow- in the flange of the propshaft is not damaged.
– Push engine/gearbox unit forwards and pull off the propshaft

from the output flange of the angle gearbox.
– Raise propshaft and tie up.

OCTAVIA II 2004 ➤

sensor -G78- .
Gr. 40 .
– Remove assembly carrier with pendulum support, anti-roll bar,
consoles, steering gear and track control arms ⇒ Chassis ⇒
Rep. Gr. 40 .
– Remove the right drive shaft from the flange shaft of the gear‐
box ⇒ Chassis ⇒ Rep. Gr. 40 and tie up (do not damage the
surface protection).
– Remove the right flange shaft bolt -arrow- using the socket
insert -T10107A- .
Note
On vehicles without particle filter, the right flange shaft remains in

the angle gearbox.

– If present, remove oil line for exhaust turbocharger -A- at en‐
gine.
– Release screws -arrows- for gearbox carrier at engine and
angle gearbox and remove gearbox carrier.
– If necessary the vacuum setting element of the charge pres‐

sure control -3- must be slightly turned to the side so that the
upper fixing screws for angle gearbox are accessible on the
manual gearbox.
– To do so, the screw -1- must be released and the screw -2-
(covered) must only be slackened. Then press the vacuum
setting element -3- slightly to the side -direction of arrow-,
while doing so do not damage the rod -4-.
– Remove particle filter with bracket for particle filter ⇒ Engine
⇒ Rep. Gr. 26 .
– Position the catch pan under the angle gearbox.

OCTAVIA II 2004 ➤
– Screw extractor -T10037- onto right flange shaft.
Note
Use the extractor -T10037- to remove the right flange shaft so that
the polygon bearings on the flange shaft are not damaged.
– Insert the thrust piece -MP3-410- between the gearbox carrier

and the knurled nut -T10037/1- .
– Align the extractor -T10037- with the support -A- parallel to the
flange.
– Take out the flange shaft.
– Remove the support -A- for exhaust gas turbocharger from the
exhaust gas turbocharger, release the hollow screw -B- and
remove the support ⇒ Engine ⇒ Rep. Gr. 21 .
– Release screws for gearbox carrier at engine and angle gear‐
box -arrows 1, 2- and -3-.
– Unscrew the bottom engine/gearbox connecting screws

-arrows-.
On certain vehicles a heat shield -arrow A- is located on the top

side of the angle gearbox.
The screw -arrow B- is accessible below the heat shield.
The screw -arrow C- is accessible above the heat shield.
– Carefully press off angle gearbox from manual gearbox, while
doing so secure it against falling.
– Take out angle gearbox.

OCTAVIA II 2004 ➤
– If the angle gearbox is replaced, the heat shield -A- must be

removed from the previous angle gearbox -arrows-
.
4.2 Install angle gearbox

– The installation occurs in reverse order, while paying attention
to the following.
Note
♦ On installed manual gearbox, lightly grease the rigid serration

at differential gear with grease for the plug serration of the
clutch disc -G 000 100- .
♦ If applicable, install the heat shield ⇒ page 106 when replacing
the angle gearbox.
♦ When attaching the angle gearbox to the manual gearbox
slowly turn the flange shaft (carefully push angle gearbox to
gearbox up to stop).
♦ Do not pull angle gearbox with the fixing screws against the
manual gearbox, otherwise the angle gearbox can tilt and the
fixing eyes can break off.
♦ Tighten gearbox/angle gearbox connecting screws crosswise
(always replace screws ⇒ Electronic Catalogue of Original
Parts ).
– Attach angle gearbox to gearbox and tighten connecting

screws crosswise.
– Install gearbox carrier at engine and angle gearbox -arrows-,
to do so pay attention to the tightening sequence of the screws
⇒ page 108 .
– If present, install oil line for exhaust turbocharger -A- at engine.

OCTAVIA II 2004 ➤

– Install gearbox carrier at engine and angle gearbox, to do so
pay attention to the tightening sequence of the screws
-arrows 1, 2- and -3- ⇒ page 108 .
– Install the support -A- for exhaust gas turbocharger, to do so
attach the support on the exhaust gas turbocharger and screw
in the hollow screw -B- with new O-rings ⇒ Engine ⇒ Rep.
Gr. 21 .
– Carefully right drive in flange shaft, to do so turn.
– Install particle filter with bracket for particle filter ⇒ Engine ⇒
Rep. Gr. 26 .
– Tighten the screw of the flange shaft -arrow 1- with socket in‐
sert -T10107A- .
– After installing the right flange shaft, check the gear oil level in
the angle gearbox ⇒ page 109 , to do so unscrew the oil filler
plug -B-.
– Attach the right drive shaft to the flange shaft of the gearbox
⇒ Chassis ⇒ Rep. Gr. 40 .
– Install assembly carrier with pendulum support, anti-roll bar,
consoles, steering gear and track control arms ⇒ Chassis ⇒
Rep. Gr. 40 .
Note
♦ As of production date 28 05 7 threaded inserts are located in

the bolt-holes for the pendulum support (e.g. “Heli-Coil”).
♦ Please observe the corresponding fixing screws and the tight‐
10 .
If the shift mechanism was removed from the gearbox:

– Attach shift mechanism to the gearbox ⇒ page 71 and adjust
shift mechanism ⇒ page 77 .
– Screw propshaft onto the flange of the angle gearbox
⇒ page 223 .
– Install all supports for exhaust system at gearbox and pre-ex‐
haust pipe ⇒ Engine ⇒ Rep. Gr. 26 .
– Assemble exhaust system free of stress and install bracket for
the exhaust system at the assembly carrier ⇒ Engine ⇒ Rep.
Gr. 26 .
– Install the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Install front wheels ⇒ Chassis ⇒ Rep. Gr. 44 .
– If the front left vehicle level sensor -G78- was removed, then
the headlight beam setting must be checked ⇒ Electrical Sys‐
tem ⇒ Rep. Gr. 94 .

OCTAVIA II 2004 ➤
4.2.1 Tightening torques

On vehicles without particle filter install gearbox carrier at engine
and angle gearbox.
When installing the gearbox carrier, observe the following mount‐
ing sequence:
– Screw in screws -arrows 1- by hand.
– Tighten screws -arrows 2- to 40 Nm.
On vehicles with particle filter install gearbox carrier at engine and

angle gearbox
Assignment of screws
Pos. Screw Pieces
1 M10 x 21 3
21) M10 x 45 2
3 M10 x 62 1
1)The head was adapted to the other screws shortly after start of
the series.
When installing the gearbox carrier, observe the following mount‐
ing sequence:
– Screw in all screws by hand.
– Tighten screws -arrows 2- and -arrow 3- to 40 Nm.
Component Tightening torque

Heat shield for angle gearbox 5 Nm
Heat shield of drive shaft to angle gearbox 20 Nm
Ventilation pipe in angle gearbox 10 Nm
Right flange shaft to gearbox ⇒ page 122
Gearbox/angle gearbox1) connecting screws ⇒ page 122
Pendulum support ⇒ Engine ⇒ Rep. Gr. 10
Vacuum setting element of charge pressure con‐ ⇒ Engine ⇒ Rep. Gr. 21
trol to exhaust turbocharger
Supports for exhaust manifold ⇒ Engine ⇒ Rep. Gr. 26
Front left vehicle level sensor -G78- ⇒ Chassis ⇒ Rep. Gr. 40
Parts .

OCTAVIA II 2004 ➤
5 Inspecting gear oil in the angle gear‐

box
5.1 Inspecting oil level in the angle gearbox

♦ Catch pan
The angle gearbox is screwed on laterally to the manual gearbox
and equipped with its own closed oil supply.
Oil specification ⇒ Electronic Catalogue of Original Parts .
Precondition
• The angle gearbox must be in its installed position.
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
Note
Cover area under the oil filler plug with cloths.
– Unscrew oil filler plug -B-.

Screw -B- must be replaced
The oil is at the correct level if the angle gearbox is filled up to the
lower edge of the oil filler hole.
If oil gets onto the angle gearbox, it must be thoroughly removed.
– Top up oil if necessary ⇒ page 109 .
– Screw in new screw -B- and tighten to tightening torque.
– Install heat shield for drive shaft, if it was removed.
Tightening torques
Component Nm
Filler screw1) 15
Heat shield of drive shaft to angle gear‐ ⇒ page 108
box
1) Always replace screw ⇒ Electronic Catalogue of Original Parts .
5.2 Top up oil in angle gearbox

5. Inspecting gear oil in the angle gearbox 109

OCTAVIA II 2004 ➤
♦ Catch pan
♦ Filling device e.g. -VAS 6291- or -VAS 6291A-
The angle gearbox is screwed on laterally to the manual gearbox
and equipped with its own closed oil supply.
Precondition
• The angle gearbox must be in its installed position.
For topping up, use filling device , e.g. -VAS 6291- or -VAS
6291A- .
– Lay hose of filling device through the engine compartment.
– On vehicles with particle filter, guide the hose of the filling de‐
vice -A- past the particle filter on the right.

OCTAVIA II 2004 ➤
Note
Cover the area below the oil filler plug -arrow- with a cloth.
– Release the oil filler plug -arrow- in the angle gearbox.
– Screw in adapter -A- up to the stop.

– Lock angular piece -B- with adapter -A-.
The hose must not sag.
– Ensure that the the valve -arrow- is closed.

– Screw oil reservoir -A- onto filling device - VAS 6291- .
– Now open valve -arrow- and hold oil reservoir as shown.
– Angle gearbox is now filled with oil.
– Raise the vehicle after several minutes.
5. Inspecting gear oil in the angle gearbox 111

OCTAVIA II 2004 ➤
Note
♦ If the angle gearbox is correctly filled, oil flows out at the

adapter -A-.
♦ If no oil flows out, lower the vehicle and continue the filling
procedure.
– Raise vehicle.
– If oil flows out, place down oil reservoir (e.g on a tool car).
One part of the excessive oil flows now back into the oil reservoir.
– If no more oil flows back, remove filling device .
– Make sure that there is still oil in the hose of the filling device .
– Screw in original oil filler plug.
– Start engine, engage a gear and allow gearbox to rotate for
about 2 minutes.
– Switch off engine and unscrew oil drain plug.
– If necessary pour in oil again up to lower edge of filler hole.
– Screw in new screw -arrow- and tighten to tightening torque.

• If oil gets onto the angle gearbox and other components, it
must be thoroughly removed.
– Install heat shield for drive shaft, if it was removed.
Tightening torques
Component Nm
Fillerscrew1) 15
box
1) Always replace screw ⇒ Electronic Catalogue of Original Parts .

OCTAVIA II 2004 ➤
6 Disassembling and assembling the

gearbox
6.1 Gearbox overview
6.1.1 Front-wheel-drive
1 - Clutch housing
2 - Reverse shaft
reverse gear
bearing
5 - Drive shaft
through 4
8 - Rigid shaft
❑ as of 11.04 replaced by
flange shaft
⇒ Item 22 (page 120)
9 - Flange shaft
10 - 2nd gear sliding gear
11 - 1st gear sliding gear
12 - 4th gear sliding gear
13 - 3rd gear sliding gear
16 - Reverse gear sliding gear
17 - Gearbox housing
6. Disassembling and assembling the gearbox 113

OCTAVIA II 2004 ➤
6.1.2 Four-wheel drive
1 - Clutch housing
2 - Reverse shaft
reverse gear
bearing
5 - Drive shaft
through 4
8 - Angle gearbox
9 - Right flange shaft
10 - Head bevel gear with drive
shaft
11 - Shank bevel gear
12 - Output flange
13 - Flange shaft left

OCTAVIA II 2004 ➤
l - Removing and installing

gearbox housing and shift
ll - Removing and installing the
drive shaft, output shafts, dif‐
ferential gear and gear shift
rods ⇒ page 119
Mounting sequence up to production date 20 01 8 ⇒ page 123
Note
The cap for the drive shaft is secured with a circlip -A- as of pro‐
duction date 21 01 8.
Mounting sequence as of production date 21 01 8 (gearbox “with”

circlip -A- for the cap/drive shaft ⇒ page 134

OCTAVIA II 2004 ➤
l - Gearbox housing and gear‐

shift mechanism - Summary of
components ⇒ page 117
ll - Drive shaft, output shafts,
differential gear, angle gear‐
box and gearshift rods - Sum‐
mary of components
⇒ page 119
Mounting sequence up to production date 20 01 8 ⇒ page 123
Note
The cap for the drive shaft is secured with a circlip -A- as of pro‐
duction date 21 01 8.
Mounting sequence as of production date 21 01 8 (gearbox “with”

circlip -A- for the cap/drive shaft ⇒ page 134

OCTAVIA II 2004 ➤
6.3 Removing and installing gearbox housing and shift mechanism
1 - 33 Nm
2 - Flange shaft with pressure
spring
⇒ page 123
❑ disassembling and as‐
sembling ⇒ page 211
3 - Circlip
❑ for cap Pos. 4
❑ installed as of produc‐
tion date 21 01 8
4 - Screw cap
❑ secured with circlip Pos.
3 as of production date
21 01 8
5 - Circlip
6 - Reversing light switch -F4- ,
20 Nm
7 - Sealing ring
tronic Catalogue of
Original Parts
8 - Oil drain plug
❑ pay attention to different
versions ⇒ page 118
❑ Internal serration screw,
45 Nm
❑ Allan screw, 30 Nm
9 - Sealing ring
❑ if present, always re‐
place ⇒ Electronic
Parts
10 - Locking screw, 45 Nm
❑ for gearshift shaft
11 - 15 Nm + torque a further 90°
❑ with captive washer
❑ Assignment of screws as replacement part ⇒ page 118
❑ without washer
❑ Assignment of screws as replacement part ⇒ page 118
13 - Gearshift unit
❑ (gearshift mechanism on the gearbox side)
❑ repairing ⇒ page 158
❑ as of 06.09, modified on the 5th/6th gear shift rod on gearboxes with bearing of the reverse gear shift
fork ⇒ page 158

OCTAVIA II 2004 ➤
❑ remove with the gearbox installed:
♦ Remove battery and battery tray
♦ Remove control cables and gearshift lever
♦ Unscrew locking screw
♦ Pull out gearshift unit, to do so the locking angle (for setting the gearshift mechanism) must not be inserted
14 - 20 Nm
15 - O-ring
16 - Clutch housing
Different versions of oil filler plug and oil drain plug.

I - Oil filler plug and oil drain plug with internal serration
II - Oil filler plug and oil drain plug with Allan key
Assignment of screws as replacement part

A - Screw with captive washer
B - Screw without washer
C - Screw with captive washer

OCTAVIA II 2004 ➤
6.4 Removing and installing the drive shaft,

output shafts, differential gear, gearshift
rods and angle gearbox
Note
♦ Fitting position of the shafts and gearshift rods in the gearbox where the reverse gear shift fork is positioned
on the shaft for reverse gear shift fork in the clutch housing ⇒ page 121 .
on the 5th/6th gear shift rod ⇒ page 121 .

through 4
2 - Gear shift rod with shift fork
for 1st and 2nd gear
for 3rd and 4th gear
reverse gear
for 5th and 6th gear
6 - Gearshift fork reverse gear
7 - Drive shaft
❑ Always replace grooved
ball bearing on the drive
shaft ⇒ page 165
8 - Reverse shaft
❑ with thrust washer
9 - Thrust washer
10 - Breather
❑ connect with slave cylin‐
der Pos. 14
11 - Clutch housing
13 - O-ring
❑ moisten with brake fluid before installing
14 - Slave cylinder with release bearing

OCTAVIA II 2004 ➤
15 - Screw
❑ for metal slave cylinder: 12 Nm (without locking agent)
❑ for plastic slave cylinder: 15 Nm (with locking agent)
❑ 3 pieces
❑ carefully tighten in small stages crosswise so that the screw-down eyes of the slave cylinder do not break
off
16 - O-ring
17 - Cap
❑ can be pushed onto the rigid shaft, or removed by hand
18 - 33 Nm
19 - Rigid shaft with pressure spring
❑ complete ⇒ page 211
❑ as of 11.04 replaced by flange shaft pos. 22
20 - Sealing ring
❑ for the right rigid shaft
21 - 33 Nm
22 - Flange shaft
❑ assign ⇒ Electronic Catalogue of Original Parts
23 - Cap
❑ release with screwdriver alternatively from the flange shaft
❑ push on by hand up to the stop
❑ must lock with the flange shaft
24 - Sealing ring
❑ for right flange shaft
❑ disassembling and assembling ⇒ page 211

OCTAVIA II 2004 ➤
Fitting position of shafts and gear shift rods in the gearbox up to

05.09
1 - Drive shaft
2 - Output shaft gears 1 through 4
3 - Output shaft 5th/6th gear/reverse gear
4 - Reverse shaft
A - Selector rod 3rd and 4th gear
B - Selector rod 1st and 2nd gear
C - Selector rod 5th and 6th gear
D - Gearshift fork reverse gear
Note
The reverse gear shift fork Pos. D is positioned on the shaft for
reverse gear shift fork in the clutch housing.
Fitting position of shafts and gear shift rods in the gearbox as of

06.09
1 - Drive shaft
4 - Reverse shaft
A - Selector rod 3rd and 4th gear
B - Selector rod 1st and 2nd gear
C - Selector rod 5th and 6th gear
Note
The reverse gear shift fork Pos. D is positioned on the 5th/6th gear
shift rod Pos. C.

OCTAVIA II 2004 ➤
Note
on the shaft for reverse gear shift fork in the clutch housing ⇒ page 121 .
on the 5th/6th gear shift rod ⇒ page 121 .

through 4
reverse gear
7 - Drive shaft
❑ Always replace grooved
ball bearing on the drive
shaft ⇒ page 165
8 - Reverse shaft
❑ with thrust washer
9 - Thrust washer
10 - Breather
❑ connect with slave cylin‐
der Pos. 14
11 - Clutch housing
13 - O-ring
❑ moisten with brake fluid before installing
14 - Slave cylinder with release bearing
15 - Screw
❑ for metal slave cylinder: 12 Nm (without locking agent)
❑ for plastic slave cylinder: 15 Nm (with locking agent)
❑ 3 pieces

OCTAVIA II 2004 ➤
❑ carefully tighten in small stages crosswise so that the screw-down eyes of the slave cylinder do not break
off
16 - 33 Nm
❑ 4 pieces
18 - Angle gearbox
❑ Removing and installing with gearbox fitted ⇒ page 101
❑ Removing and installing with gearbox removed ⇒ page 123
❑ disassembling and assembling ⇒ page 211
6.5 Mounting sequence up to production

date 20 01 8
Removing and installing the gearbox housing, shift mechanism,
drive shaft, output shafts, differential gear, gear shift rods and
angle gearbox
♦ Press-on sleeve -MP3-412 (VW 455)-
♦ Multi-purpose tool -MP3-419 (VW 771)-
♦ Supporting bridge -MP3-425 (30-211A)-
♦ Assembly stand -MP9-101-
♦ Retaining plate -T30108-
♦ Gearbox mount -T30109 (VW 353)-
♦ Separating device , e.g. -Kukko 17/0 -
♦ Hot-air blower
♦ Catch pan
♦ Ring bolt -3368-
♦ Sealant -AMV 188 200 03-

OCTAVIA II 2004 ➤
6.5.1 Disassembling gearbox

Four-wheel drive
insert -T10107A- .
Note
The right flange shaft remains in the angle gearbox.

-arrows-.

Continued for all gearboxes
Note
Before disassembling the gearbox first the gearbox mount -

T30109 (VW 353)- should be secured to the gearbox
⇒ page 125 .

OCTAVIA II 2004 ➤
Secure the
gearbox mount -T30109 (VW 353)- to the gearbox
.
– Attach gearbox to assembly stand -MP9-101- .

– Place catch pan underneath.
– Drain out gear oil.

OCTAVIA II 2004 ➤
Please make sure during the following work step that the gearshift
shaft is not blocked by the locking angle -arrow-.
– Put the gearshift shaft into Neutral.
– Remove switch for reversing lights -F4- -1-.
– Unscrew locking screw -2-.
– Release screws -3-.
– Pull the gearshift shaft -4- out of the gearbox housing.
– Remove the left flange shaft.
Front-wheel-drive
– Remove rigid shaft or right flange shaft.
Note
For gearboxes as of production date 11.04, the rigid shaft (right)

was replaced by a flange shaft.
– Unscrew screws -B-, that serve to secure the gearbox housing

from the clutch housing.
Note
The hexagon bolt -arrow- is located outside the screw-on flange.

It is fitted with a washer.
– Interlock the drive shaft by fitting the press-on sleeve -VW 455
(MP3-412)- via the drive shaft onto the clutch housing.

OCTAVIA II 2004 ➤
Note
If necessary the bushing -3160 (T30102)- must be used instead

of the insertion bushing -VW 455 (MP3-412)- so that the sepa‐
rating device -A- can be tensioned behind the splines of the drive
shaft.
– Tighten the separating device -A-, e. g. -Kukko 17/0- behind

the splines of the drive shaft.
While doing so the reverse side of the separating device must rest
on the insertion bushing -VW 455 (MP3-412)- or on the bushing
-3160 (T30102)- with no play.
– Push the rubber through the middle of the cap -1- using a
screwdriver .
– Carefully lever up the cap from the gearbox housing using the
screwdriver -2-.
Remove the circlip -C- from the grooved ball bearing of the drive
shaft/gearbox housing as follows:
– with the screw driver -A- hold one end of the circlip.
– With the screw driver -B- lever the other end out of the slot of
the grooved ball bearing -direction of arrow-.
– Move screwdriver -B- around, levering out the circlip step by
step.
– If applicable, remove the washer -1- from the gearbox housing

-2-.
• If the gearbox housing is replaced, check whether the washer
-1- must be fitted again ⇒ page 130 .

OCTAVIA II 2004 ➤
– Remove the fixing screws -A- for the gearbox housing on the
clutch housing.
– Screw adapter -MP3-419/40 - into the threaded hole of the

gearbox housing.
– Heat the gearbox housing with the hot-air blower at the bearing
assembly for grooved ball bearing/drive shaft to about 100°C
for around 10 minutes.
– Remove the gearbox housing from the clutch housing using
the multi-purpose tool -MP3-419/1- -direction of arrow-.
Note
If necessary carefully release with assembly lever alternatively

from the projecting housing lands and make sure the sealing sur‐
faces are not damaged in the process.
– Remove the separating device -A- and the insertion bushing -

VW 455 (MP3-412)- or the bushing -3160 (T30102)- from the
drive shaft.
– If applicable, remove the washer -1- from the grooved ball

bearing -2-.
– If the gearbox housing is replaced, check whether the washer
-1- must be fitted again ⇒ page 131 .
For the removal of the shafts from the clutch housing a second
mechanic is required.

OCTAVIA II 2004 ➤
– Lift the differential gear -1- with the left hand. With the right
hand lift output shaft gears 1 through 4 together with gear shift
rods -2- -arrow A-.
– At the same time the 2nd mechanic lifts the drive shaft, the
reverse shaft and the output shaft 5th/6th gear -3- together
with the gear shift rods out of the clutch housing -arrow B-.
Note
If necessary the differential gear can be placed again in the clutch

housing after lifting the shafts.
– Removing gasket ring for drive shaft.
Note
The grooved ball bearing on the drive shaft must always be re‐
placed ⇒ page 165 .
6.5.2 Assembling gearbox

• A new grooved ball bearing must be pressed onto the drive
shaft ⇒ page 165 .
– Insert the drive shaft -1-, the output shaft 5th/6th gear -2- to‐
gether with gear shift rod -3-, shift fork -4- and reverse shaft
-5-.
– Insert differential gear -1-.

– Take the output shaft gears 1 through 4 -3- with the gear shift
rods -4- in the right hand as shown.
– Slightly lift the differential gear with the left hand.
output shaft 5th/6th gear and reverse gear -2- together with
the reverse shaft.
– Insert the output shaft gears 1 through 4 in
-the direction of the arrow-.
The serrations of the drive shaft, output shafts and final drive/
differential gear must be in mesh.
– Place the shafts and the differential gear in their bearing as‐
sembly.

OCTAVIA II 2004 ➤
– Secure the supporting bridge -MP3-425- for drive shaft to the

clutch housing.
Note
To provide a clearer illustration, the clutch housing is shown at an

angle of 180°.
– Screw in screw -A- until the drive shaft is lifted slightly.
On certain gearboxes, flattened parts -A- are present at the

grooved ball bearing for the drive shaft and at the bearing support
-B-.
Check the grooved ball bearing for the drive shaft and the gearbox
housing.
Grooved ball bearing for the drive shaft and the gearbox housing
no flattened parts at the grooved ball bearing -A- and at the
bearing support -B- ⇒ page 130
Flattened parts at the grooved ball bearing -A- and at the bear‐
ing support -B- ⇒ page 131
As of production date 20 03 06 up to approx. production date 20
01 8:
A washer is inserted above and below the grooved ball bearing
for the drive shaft ⇒ page 165 .
Top washer Outer diameter 78.6 mm
Bottom washer Outer diameter 85 mm
Measure the shoulder above the support for the grooved ball
bearing
Shoulder above the Dimension “a” Top washer
grooved ball bearing
up to production 10 mm no
date 19 03 6
as of production 10.7 mm yes
date 20 03 6

OCTAVIA II 2004 ➤
In the gearbox housing the area below the bearing pedestal for
the grooved ball bearing is also changed -arrow-
Area below the bearing pedestal Bottom washer
up to production not chamfered. no
date 19 03 6
as of production chamfered slightly yes
date 20 03 6 deeper.
– If necessary place a washer (outside diameter = 85 mm) -1-

onto the grooved ball bearing -2-.
For certain gearboxes:

If flattened parts -A- are present at the grooved ball bearing/drive
shaft and at the bearing support -B- for the grooved ball bearing
in the gearbox housing.
• Washers must not be placed above and below the grooved
ball bearing on these gearboxes.
• The flattened parts -A- at the grooved ball bearing and at the
bearing support -B- must be aligned in the gearbox housing.
– Mark these flattened parts in different colours.
– Transfer the markings onto the upper area of the grooved ball
bearing and onto the upper area of the bearing support of the
gearbox housing (⇒ next figure).
– On all gearboxes, heat the gearbox housing with the hot-air
blower in the area of the bearing assembly for grooved ball
bearing/drive shaft to 100°C for approx. 10 minutes.
Note
♦ Warming up is necessary so that the grooved ball bearing is

not damaged when installing the gearbox housing.
♦ Apply sealant -AMV 188 200 03- uniformly on the sealing sur‐
face of the clutch housing.
♦ Align the marking of the grooved ball bearing -A- to the mark‐
ing on the gearbox housing -B- and position gearbox housing.

OCTAVIA II 2004 ➤
– Tighten new screws -A-, -B- and -C- for the gearbox housing
at the clutch housing to tightening torque.
Assignment of screws:
– If necessary place a washer -1- (outside diameter = 78.6 mm)

above the grooved ball bearing -2-.
Note
♦ If a washer must be placed onto the grooved ball bearing

⇒ page 130 .
♦ The washer -1- above the grooved ball bearing -2- is no longer
fitted if there is a flattened part on the grooved ball bearing and
the gearbox housing ⇒ page 131 .
– Install circlip -1- for grooved ball bearing/drive shaft.

– Remove supporting bridge - MP3-425- for drive shaft.
– In case the serrated sleeve for the gearshift shaft was re‐
moved, drive it in with the drift ⇒ page 147 up to the stop of
the tool.
– Turn the gearbox with the opening for the gearshift shaft in the
assembly stand upwards.
– Insert the gearshift shaft -1- into the bottom bearing -2- and
into the gearshift forks -3-. The cap in the illustration is re‐
moved for purposes of clear presentation.

OCTAVIA II 2004 ➤
– Press the gearshift shaft -1- against the serrated sleeve -2-
-direction of arrow- and guide with the shift finger -3- through
the gearshift forks up to the stop downwards.
• The gearshift cover -4- must be positioned at the same time
parallel to the screw-on surface at the gearbox housing.
• The gearshift shaft must slide easily into the selector move‐
ment (upwards and downwards).
Note
If the gearshift cover is positioned obliquely to the screw-on sur‐

face, the gearshift shaft is not inserted into the bottom bearing.
– Tighten screws -3- for the cover/gearshift shaft -4-.

– Screw in locking screw -2-, at the same time the locking angle
-arrow- must be laid out.
– Install switch for reversing lights -F4- -1-.
– Install left flange shaft with pressure spring, stop disc and con‐
ical ring.
Front-wheel-drive
– Install rigid shaft or right flange shaft with pressure spring, stop
disc and conical ring.
Note
For gearboxes as of production date 11.04, the rigid shaft (right)

was replaced by a flange shaft.
– Drive in the gasket ring for the drive shaft.

– Shift through all gears consecutively.

OCTAVIA II 2004 ➤
– Drive the cap into the gearbox housing as far as the stop of
the pressure plate -T10042- .
– Remove gearbox from assembly stand.
Four-wheel drive
Install angle gearbox as follows at the manual gearbox:
– On manual gearbox, lightly grease the rigid serration at differ‐
ential gear with grease for the plug serration of the clutch disc
- G 000 100- .
– Push angle gearbox fully onto the manual gearbox, while do‐
ing so slowly turn the flange shaft (carefully press angle gear‐
box onto gearbox up to stop).
Note
Parts ).

screws crosswise to tightening torque ⇒ Item 17 (page 123) .
sert -T10107A- to tightening torque ⇒ Item 16 (page 123) .
6.6 Mounting sequence as of production

date 21 01 8 (gearbox “with” circlip -A-
for the cap/drive shaft)
Removing and installing the gearbox housing, shift mechanism,
drive shaft, output shafts, differential gear, gear shift rods and
angle gearbox

♦ Press-on sleeve -MP3-412 (VW 455)-
♦ Supporting bridge -MP3-425 (30-211A)-

OCTAVIA II 2004 ➤

♦ Retaining plate -T30108-
♦ Hot-air blower
♦ Catch pan
♦ Ring bolt -3368-
♦ Sealant -AMV 188 200 03-
6.6.1 Disassembling gearbox

Four-wheel drive
insert -T10107A- .
Note
The right flange shaft remains in the angle gearbox.

-arrows-.

Note
Before disassembling the gearbox first the gearbox mount -

T30109 (VW 353)- should be secured to the gearbox
⇒ page 136 .

OCTAVIA II 2004 ➤
Secure the
gearbox mount -T30109 (VW 353)- to the gearbox
.
– Attach gearbox to assembly stand -MP9-101- .

– Place catch pan underneath.
– Drain out gear oil.

OCTAVIA II 2004 ➤
Please make sure during the following work step that the gearshift
shaft is not blocked by the locking angle -arrow-.
– Put the gearshift shaft into Neutral.
– Remove switch for reversing lights -F4- -1-.
– Unscrew locking screw -2-.
– Unscrew bolts -3-.
– Pull the gearshift shaft -4- out of the gearbox housing.
– Remove the left flange shaft.
Front-wheel-drive
– Removing the right flange shaft.
– Unscrew screws -B-, that serve to secure the gearbox housing

from the clutch housing.
Note
The hexagon bolt -arrow- is located outside the screw-on flange.

It is fitted with a washer.
– Interlock the drive shaft by fitting the press-on sleeve - VW 455

(MP3-412)- via the drive shaft onto the clutch housing.
Note
If necessary the bushing -3160 (T30102)- must be used instead

of the insertion bushing -VW 455 (MP3-412)- so that the sepa‐
rating device -A- can be tensioned behind the splines of the drive
shaft.
– Tighten the separating device -A-, e. g. -Kukko 17/0- behind

the splines of the drive shaft.
While doing so the reverse side of the separating device must rest
on the insertion bushing -VW 455 (MP3-412)- or on the bushing
-3160 (T30102)- with no play.

OCTAVIA II 2004 ➤
– Remove circlip -A- for the cap/drive shaft.
– Push the rubber through the middle of the cap -1- using a
screwdriver .
– Carefully lever up the cap from the gearbox housing using the
screwdriver -2-.
Remove the circlip -C- from the grooved ball bearing of the drive
shaft/gearbox housing as follows:
– with the screw driver -A- hold one end of the circlip.
– With the screw driver -B- lever the other end out of the slot of
the grooved ball bearing -direction of arrow-.
– Move screwdriver -B- around, levering out the circlip step by
step.
– Remove the fixing screws -A- for the gearbox housing on the
clutch housing.

OCTAVIA II 2004 ➤
– Screw adapter -MP3-419/40 - into the threaded hole of the

gearbox housing.
– Heat the gearbox housing with the hot-air blower at the bearing
assembly for grooved ball bearing/drive shaft to about 100°C
for around 10 minutes.
– Remove the gearbox housing from the clutch housing using
the multi-purpose tool -MP3-419/1- -direction of arrow-.
Note
If necessary carefully release with assembly lever alternatively

from the projecting housing lands and make sure the sealing sur‐
faces are not damaged in the process.
– Remove the separating device -A- and the insertion bushing -

VW 455 (MP3-412)- or the bushing -3160 (T30102)- from the
drive shaft.
For the removal of the shafts from the clutch housing a second
mechanic is required.
– Lift the differential gear -1- with the left hand. With the right
hand lift output shaft gears 1 through 4 together with gear shift
rods -2- -arrow A-.
reverse shaft and the output shaft 5th/6th gear -3- together
with the gear shift rods out of the clutch housing -arrow B-.
Note
If necessary the differential gear can be placed again in the clutch

housing after lifting the shafts.
– Removing gasket ring for drive shaft.
Note
The grooved ball bearing on the drive shaft must always be re‐
placed ⇒ page 165 .
6.6.2 Assembling gearbox

• A new grooved ball bearing must be pressed onto the drive
shaft ⇒ page 165 .

OCTAVIA II 2004 ➤
Gearbox up to 05.09
-5-.
Gearbox as of 06.09
– Place the reverse gear shift fork -4- on the 5th/6th gear shift
rod -3- in its installed position ⇒ page 140 .
-5-.
• The shift gate -arrow A- of the reverse gear shift fork points to
the outer side of the gearbox. The shift gate -arrow B- of the
5th/6th gear shift rod must point to the inner side of the gear‐
box.
– Insert differential gear -1-.

– Take the output shaft gears 1 through 4 -3- with the gear shift
rods -4- in the right hand as shown.
– Slightly lift the differential gear with the left hand.
output shaft 5th/6th gear and reverse gear -2- together with
the reverse shaft.
– Insert the output shaft gears 1 through 4 in
The serrations of the drive shaft, output shafts and final drive/
differential gear must be in mesh.
– Place the shafts and the differential gear in their bearing as‐
sembly.
– Secure the supporting bridge -MP3-425- for drive shaft to the

clutch housing.
Note
To provide a clearer illustration, the clutch housing is shown at an

angle of 180°.
– Screw in screw -A- until the drive shaft is lifted slightly.

OCTAVIA II 2004 ➤
The grooved ball bearing/drive shaft only fits in one position in the
gearbox housing
One flattened part is located at the grooved ball bearing/drive
shaft and at the bearing support for the grooved ball bearing in
the gearbox housing.
• If the flattened parts -A- and -B- are present, a washer must
not be inserted above and below the grooved ball bearing/
drive shaft ⇒ page 169 .
• The flattened parts -A- at the grooved ball bearing and at the
bearing support -B- must be aligned in the gearbox housing.
– Mark these flattened parts in different colours.
– Transfer the markings onto the upper area of the grooved ball
bearing and onto the upper area of the bearing support of the
gearbox housing (⇒ next figure).
– Heat the gearbox housing with the hot-air blower in the area
of the bearing assembly for grooved ball bearing/drive shaft to
100°C for approx. 10 minutes.
Note
♦ Warming up is necessary so that the grooved ball bearing is

not damaged when installing the gearbox housing.
♦ Apply sealant -AMV 188 200 03- uniformly on the sealing sur‐
face of the clutch housing.
♦ Align the marking of the grooved ball bearing -A- to the mark‐
ing on the gearbox housing -B- and position gearbox housing.
– Tighten new screws -A-, -B- and -C- for the gearbox housing
at the clutch housing to tightening torque.
Assignment of screws:

OCTAVIA II 2004 ➤
– Install circlip -1- for grooved ball bearing/drive shaft.

– Remove supporting bridge -MP3-425- for drive shaft.
– In case the serrated sleeve for the gearshift shaft was re‐
moved, drive it in with the drift ⇒ page 147 up to the stop of
the tool.
– Turn the gearbox with the opening for the gearshift shaft in the
assembly stand upwards.
– Insert the gearshift shaft -1- into the bottom bearing -2- and
into the gearshift forks -3-. The cap in the illustration is re‐
moved for purposes of clear presentation.
– Press the gearshift shaft -1- against the serrated sleeve -2-
-direction of arrow- and guide with the shift finger -3- through
the gearshift forks up to the stop downwards.
• The gearshift cover -4- must be positioned at the same time
parallel to the screw-on surface at the gearbox housing.
• The gearshift shaft must slide easily into the selector move‐
ment (upwards and downwards).
Note
If the gearshift cover is positioned obliquely to the screw-on sur‐

face, the gearshift shaft is not inserted into the bottom bearing.
– Tighten screws -3- for the cover/gearshift shaft -4-.

– Screw in locking screw -2-, at the same time the locking angle
-arrow- must be laid out.
– Install switch for reversing lights -F4- -1-.

OCTAVIA II 2004 ➤
– Install left flange shaft with pressure spring, stop disc and con‐
ical ring.
Front-wheel-drive
– Install right flange shaft with pressure spring, stop disc and
conical ring.
– Drive in the gasket ring for the drive shaft.

– Shift through all gears consecutively.
– Drive the cap into the gearbox housing up to the stop.

OCTAVIA II 2004 ➤
– Secure cap with circlip -A-.

– Remove gearbox from assembly stand.
Four-wheel drive
Install angle gearbox as follows at the manual gearbox:
– On manual gearbox, lightly grease the rigid serration at differ‐
ential gear with grease for the plug serration of the clutch disc
- G 000 100- .
– Push angle gearbox fully onto the manual gearbox, while do‐
ing so slowly turn the flange shaft (carefully press angle gear‐
box onto gearbox up to stop).
Note
Parts ).

screws crosswise to tightening torque ⇒ Item 17 (page 123) .
sert -T10107A- to tightening torque ⇒ Item 16 (page 123) .

OCTAVIA II 2004 ➤
7 Repairing gearbox housing
7.1 Summary of components - Gearbox housing
1 - Gearbox housing
❑ when replacing: Set the
output shafts and the
differential gear
⇒ page 210
❑ Modifications in the area
of the support for the
grooved ball bearing/
drive shaft ⇒ page 165
❑ assign components via
⇒ Electronic Catalogue
of Original Parts
2 - Screw cap
❑ removing ⇒ page 147
❑ inserting ⇒ page 147
3 - Oil drain plug
version ⇒ page 118
45 Nm
4 - Sealing ring
❑ if present, always re‐
place ⇒ Electronic
Parts
5 - Oil filler plug
versions ⇒ page 118
45 Nm
6 - Locking angle
❑ for setting the gearshift mechanism ⇒ page 77
❑ can be replaced without disassembling gearbox
7 - Bushing
❑ for selector rods
8 - Serrated sleeve
❑ press out with gearbox disassembled ⇒ page 149
❑ drive out without disassembling gearbox ⇒ page 149
❑ Difference between serrated sleeves ⇒ page 149
❑ Drive in serrated sleeve with shoulder ⇒ page 149
7. Repairing gearbox housing 145

OCTAVIA II 2004 ➤
❑ Drive in serrated sleeve without shoulder ⇒ page 149
9 - Needle bushing
❑ for reverse shaft
❑ replace after each disassembly ⇒ electronic catalogue of original parts
10 - Outer ring/tapered-roller bearing
❑ for output shaft 5th/6th and reverse gear
❑ when replacing: Set output shaft 5th/6th and reverse gear ⇒ page 193
11 - Adjusting washer
❑ Setting overview ⇒ page 210
❑ for output shaft gears 1 through 4
❑ when replacing: Set output shaft gears 1 through 4 ⇒ page 182
❑ for differential gear
❑ when replacing: Set the differential gear ⇒ page 220
16 - Bushing
17 - Plug
❑ drive out with drift
18 - Sealing ring

OCTAVIA II 2004 ➤
7.2 Repairing gearbox housing

♦ Drive bushing -MP3-402 (VW 244B)-
♦ Pressure plate -MP3-406 (VW 401)-
♦ Thrust piece -MP3-420 (3124)-
♦ Pressure spindle -MP3-423 (VW 407)-
♦ Guide piece -MP3-454 (VW 439)-
♦ Pipe section -MP3-4012 (VW 416B)-
♦ Retaining plate -T30027 (VW 801)-
♦ Guide bolt -T30074 (10 - 15)-
♦ Mandrel -T30083 (3264)-
♦ Assembly device -T30100 (3290)-
♦ Drift -T10168-
♦ Drift -T10169- or Drift -T10362- ⇒ page 149
♦ Interior extractor e.g. -Kukko 21/2-
♦ Countersupport e.g. -Kukko 22/2 -
Removing cap -A-
– Push the rubber through the middle of the cap using a screw‐
driver -B- and lever out the cap -direction of arrow-.
Drive in cap up to the stop
Removing locking angle for gearshift shaft

– Remove angle in the released position.
– Insert a screwdriver -A- in the hole of the locking angle -B-.
– Lever out inner part of locking angle in

OCTAVIA II 2004 ➤
Fitting position of locking angle

– The marking on the locking angle -arrow- must point to the
connection of the slave cylinder -1-.
The dimension -a- must be approx. 45°.
Drive in locking angle -arrow- for gearshift shaft up to the stop of

the tool
Note
Locking angle must be released during drive-in procedure.
Remove bushing for gear shift rod

A - Interior extractor 14.5...18.5 mm , e.g. -Kukko 21/2 -
B - Countersupport , e.g. -Kukko 22/2-
Note
After removing the bushing check for damage, if necessary re‐

place.
Drive in the bushing for the shift rod up to the stop of the tool

OCTAVIA II 2004 ➤
Press serrated sleeve -A- out of gearbox housing

– Position the gearbox housing on the pressure plates -
MP3-406- and -MP3-407- in such a way that the dowel sleeves
in the gearbox housing are not damaged.
Drive out serrated sleeve without disassembling gearbox with

guide bolts -T30074-
– First remove locking screw and gearshift shaft.
– Turn the gearbox in such a way that the serrated sleeve does
not fall into the gearbox.
Difference between serrated sleeves

A serrated sleeve can be fitted with shoulder -arrow 1-
⇒ page 149 and without shoulder -arrow 2- ⇒ page 149 .
Assign components via the ⇒ Electronic catalogue of original
parts .
Drive in serrated sleeve up to the stop of the tool

A - Drive in serrated sleeve with shoulder, drift -T10169- .
B - Drive in serrated sleeve without shoulder, drift -T10362- .
• Gearbox housing screwed to clutch housing.

OCTAVIA II 2004 ➤
Pull needle bushing for reverse shaft out of the gearbox housing
A - Interior extractor 23.5...30 mm , e.g. -Kukko 21/4-
Note
The needle bushing is damaged when removed and must be re‐

placed.
Pressing in needle bushing -A- in the gearbox housing

– During press-in procedure, position the thrust washer -A- of
the reverse shaft onto the needle bushing.
– Support the gearbox housing with a pipe section -MP3-4012-
directly below the bearing support.
Remove bushing for gearshift shaft

– Hold spindle of assembly device -T30100- and turn nut -B-.
A - Interior extractor 14.5...18.5 mm , e.g. -Kukko 21/2-
Drive in the bushing -A- for the gearshift shaft up to the stop of
the tool.

OCTAVIA II 2004 ➤
Driving in plug
– Drive in plug -1- with the mandrel -T30083- to the dimension
-a- = approx. 3 mm below the upper edge of the housing.

OCTAVIA II 2004 ➤
8 Repairing clutch housing
8.1 Summary of components - Front-wheel-drive
1 - Bushing
2 - Shaft for reverse gear shift
fork
❑ Shaft cannot be re‐
moved with workshop
tools
❑ Press shaft into the
clutch housing
⇒ page 157
❑ Modification as of 06.09:
on gearboxes where the
reverse gear shift fork is
positioned on the 5th/
6th gear shift rod, the
shaft is not fitted
3 - Needle bushing
❑ replace after each dis‐
assembly ⇒ electronic
catalogue of original
parts
4 - Fitting sleeve
❑ 2 pieces
5 - Clutch housing
differential gear
⇒ page 210
❑ Modification as of 06.09: on gearboxes where the reverse gear shift fork is positioned on the 5th/6th gear
shift rod, the shaft for reverse gear shift fork is not fitted
❑ assign according to ⇒ Electronic Catalogue of Original Parts
7 - Sealing ring
❑ for rigid shaft, gearbox up to production date 10.04
❑ for flange shaft, gearbox as of production date 11.04
8 - Washer
❑ Fitting position: the shoulder on the inside diameter points towards the gasket ring Pos. 7

OCTAVIA II 2004 ➤

❑ for the differential gear
10 - Oil deflecting washer
❑ Fitting position: The shoulder on the hole points to the output shaft
13 - Washer
❑ always 0.65 mm thick
14 - Cylindrical-roller bearing
❑ for drive shaft
15 - Magnet
❑ is held in position by the separator surface of the housing
16 - Cap
❑ not fitted to all clutch housings
8. Repairing clutch housing 153

OCTAVIA II 2004 ➤
8.2 Summary of components - Four-wheel drive
1 - Bushing
2 - Shaft for reverse gear shift
fork
❑ Shaft cannot be re‐
moved with workshop
tools
❑ When using a new
clutch housing a new
shaft must be pressed in
⇒ page 157
❑ Modification as of 06.09:
on gearboxes where the
reverse gear shift fork is
positioned on the 5th/
6th gear shift rod, the
shaft is not fitted
3 - Needle bushing
❑ replace after each dis‐
assembly ⇒ electronic
catalogue of original
parts
4 - Fitting sleeve
❑ 2 pieces
5 - Clutch housing
differential gear
⇒ page 210
❑ Modification as of 06.09: on gearboxes where the reverse gear shift fork is positioned on the 5th/6th gear
shift rod, the shaft for reverse gear shift fork is not fitted
❑ assign according to ⇒ Electronic Catalogue of Original Parts
7 - Sealing ring
❑ between manual gearbox and angle gearbox
❑ replace with installed gearbox ⇒ page 203
❑ pull out using ejection lever -MP3-418- or extraction hook -T20143-
❑ on disassembled gearbox it can be driven in with pressure plate -T40007 - up to the stop
8 - Washer
❑ for the differential gear

OCTAVIA II 2004 ➤
❑ Fitting position: The shoulder on the hole points to the output shaft
13 - Washer
❑ for drive shaft
15 - Magnet
❑ is held in position by the separator surface of the housing
16 - Cap
❑ not fitted to all clutch housings
8.3 Repairing clutch housing

♦ Drift -T10168-
♦ Countersupport e.g. -Kukko 22/1-
Remove bushing for gear shift rod
A - Countersupport , e.g. -Kukko 22/1-
B - Interior extractor 14.5...18.5 mm , e.g. -Kukko 21/2-
Note
After removing the bushing check for damage, if necessary re‐

place.

OCTAVIA II 2004 ➤
Drive in the bushing for the shift rod up to the stop of the tool
Removing needle bushing from clutch housing

B - Interior extractor 23.5...30 mm , e.g. -Kukko 21/4-
Note
The needle bushing is damaged when removed and must be re‐

placed.
Pressing in needle bushing -A- in the clutch housing

– During press-in procedure, position the thrust washer -B- of
the reverse shaft onto the needle bushing -A-.
Removing gasket ring for drive shaft

– Carefully lever out gasket ring with screwdriver.
Note
♦ Do not damage contact surface for shaft seal on the drive

shaft.
♦ The gasket ring can also be removed with the extraction hook
-T20143/1- .

OCTAVIA II 2004 ➤
Insert the gasket ring for the drive shaft until flush
Press shaft for reverse gear shift fork into the clutch housing

OCTAVIA II 2004 ➤
9 Repairing gearshift unit

♦ Pipe section -MP3-479 (VW 423)-
♦ Extraction hook -T20143/1-
Note
Coat bearings and friction surfaces with grease - G 000 450 02- .
1 - 23 Nm
❑ self-locking
tronic Catalogue of
Original Parts
2 - Gearshift lever
❑ insert in such a way that
the interrupted spacing
of the teeth matches the
gearshift shaft
❑ may be replaced with
the gearshift mecha‐
nism mounted
⇒ page 66
3 - Sliding shoe
❑ clip into relay lever Pos.
5
4 - Bushing
❑ is not required for plastic
relay lever
5 - Reversing lever
❑ out of plastic or metal
❑ Metal relay lever is loca‐
ted in the bushings Pos.
4 and secured with a
lock washer Pos. 10
❑ as of 03.07 plastic relay
lever ⇒ page 70
⇒ page 66
6 - Gearshift shaft
❑ with cover
❑ Difference between the gearshift shafts in the area of the lower shift finger -arrow- ⇒ page 159
❑ can be installed or removed with the gearbox mounted
7 - Bushing

OCTAVIA II 2004 ➤
8 - O-ring
❑ insert into the round slot of the gearshift cover
❑ insert with gear oil
9 - Cap
❑ for gearbox bleeder
10 - Lock washer
❑ for bell crank lever
11 - Sealing ring
❑ remove with screwdriver or with extraction hook -T20143/1- ⇒ page 159
Remove lock washer for bell crank lever

– Lift retaining clip in the -direction of the arrow-.
Difference between the gearshift shafts

A - previous gearshift shaft (up to 05.09) with 2 shift fingers
-arrow 1- and -arrow 2- in the lower area of the gearshift shaft
• Fit this gearshift shaft on gearboxes where the reverse gear
shift fork is positioned on the shaft for reverse gear shift fork
in the clutch housing.
B - modified gearshift shaft (as of 06.09) with 1 shift finger
-arrow 3- in the lower area of the gearshift shaft
• Fit this gearshift shaft on gearboxes where the reverse gear
shift fork is positioned on the 5th/6th gear shift rod.
Remove gasket ring with ejection hook -T20143/1-
9. Repairing gearshift unit 159

OCTAVIA II 2004 ➤
Insert gasket ring up to the stop with pipe section -MP3-479 (VW
423)-

OCTAVIA II 2004 ➤
10 Disassembling and assembling the

gearshift forks
10.1 Disassembling and assembling gear‐

shift forks up to 05.09
♦ Thrust piece -MP3-453 (VW 431) -
♦ Thrust piece with spacer sleeve -MP3-458 (VW 472)-
Note
♦ The reverse gear shift fork Pos. 5 is positioned on the shaft for reverse gear shift fork in the clutch housing.
♦ Fitting position of gearshift forks and gear shift rods in the gearbox ⇒ page 162 .
10. Disassembling and assembling the gearshift forks 161

OCTAVIA II 2004 ➤
1 - Rubber insulation
❑ can be pulled out of the
gear shift rod and inser‐
ted by hand
❑ the ball sleeve is no lon‐
ger fitted as of produc‐
tion date 03.06
⇒ page 163
❑ Time of application is
flexible
❑ the reverse gear shift
fork is adapted
❑ Difference between the
reverse gear shift forks
⇒ page 163
6 - Ball sleeve
❑ the ball sleeve is no lon‐
ger fitted as of produc‐
tion date 03.06
❑ Time of application is
flexible
Fitting position of gearshift forks and gear shift rods in the gearbox
1 - Drive shaft
4 - Reverse shaft
A - Gear shift rod with 3rd and 4th gear shift fork
B - Gear shift rod with 1st and 2nd gear shift fork
C - Gear shift rod with 5th and 6th gear shift fork

OCTAVIA II 2004 ➤
Difference between the reverse gear shift forks

Dimension “a” mm Production date
24 up to 05 03 6
18 as of 06 03 6
Up to production date 03.06 - remove ball sleeve for reverse gear

shift fork
A - Interior extractor 18...23 mm , e.g. -Kukko 21/3-
Up to production date 03.06 - press in ball sleeve for reverse gear

shift fork
10. Disassembling and assembling the gearshift forks 163

OCTAVIA II 2004 ➤
10.2 Disassembling and assembling the gearshift forks as of 06.09
Note
♦ The reverse gear shift fork Pos. 5 is positioned on the 5th/6th gear shift rod.
♦ Fitting position of gearshift forks and gear shift rods in the gearbox ⇒ page 164 .
1 - Rubber insulation
❑ can be pulled out of the
gear shift rod and inser‐
ted by hand
Fitting position of gearshift forks and gear shift rods in the gearbox
1 - Drive shaft
4 - Reverse shaft
A - Gear shift rod with 3rd and 4th gear shift fork
B - Gear shift rod with 1st and 2nd gear shift fork
C - Gear shift rod with 5th and 6th gear shift fork

OCTAVIA II 2004 ➤
35 – Wheels, shafts
1 Drive shaft
1.1 Disassembling and assembling the

drive shaft
♦ Thrust piece -MP3-453 (VW431)-
♦ Thrust piece - MP3-4014 (VW 432)-
♦ Drift pin -MP3-426 (30-505)-
♦ Thrust plate -MP3-467 (40-105)-
♦ Pipe section -T30041 (2040)-
♦ Extractor , e.g. -Kukko 18/1 -
Note
Insert all bearings on the drive shaft with gear oil.
1. Drive shaft 165

OCTAVIA II 2004 ➤
1 - Circlip
⇒ page 123
2 - Washer
❑ Outer diameter = 78.6
mm
❑ can only be used on
modified gearbox hous‐
ings (as of production
date 04.06 up to 01.08)
⇒ page 169
of Original Parts
3 - Gearbox housing
❑ adapted for the washers
Pos. 2 and Pos. 4 as of
production date 04 06
up to production date
01.08 in the area of the
bearing pedestal for the
Pos. 6 ⇒ page 169
❑ flattened parts at the
and at the bearing ped‐
estal of the grooved ball
bearing as of production
date 02.08 ⇒ page 170
of Original Parts
4 - Washer
❑ Outer diameter = 85 mm
❑ can only be used on
modified gearbox hous‐
ings (as of production date 04.06 up to 01.08) ⇒ page 169
❑ assign components via ⇒ Electronic Catalogue of Original Parts
5 - Circlip
❑ determine ⇒ page 168 when replacing the grooved ball bearing -Pos. 6- and the drive shaft -Pos. 8-
6 - Grooved ball bearing
❑ flattened parts at the grooved ball bearing and at the bearing pedestal of the grooved ball bearing as of
production date 02.08 ⇒ page 170
❑ remove ⇒ page 167
❑ pressing on ⇒ page 168
7 - 5th gear pinion
❑ pressing off ⇒ page 167
❑ Fitting position: round groove -arrow- points to the grooved ball bearing Pos. 6
8 - Drive shaft
❑ with 3rd/4th gear pinon and 6th gear
❑ with circlip
166 Rep. Gr.35 - Wheels, shafts

OCTAVIA II 2004 ➤
❑ Fitting position: the circlip in the bearing points towards the drive shaft
10 - Clutch housing
Remove grooved ball bearing

– First remove the circlip from the drive shaft.
– Before fitting the extractor position thrust piece -MP3-453- and
pressure plate -MP3-467- on drive shaft.
– Position the separating device -B- in the round slot for the cir‐
clip in the bearing.
A - Extractor , e.g. -Kukko 18/1-
B - Separating device 12...75 mm , e.g. -Kukko 17/1-
Pressing out 5th gear pinion

A - Separating device 22...115 mm , e.g. -Kukko 17/2-
Pressing on 5th gear pinion

The groove -arrow- on the gearwheel must point upwards.
1. Drive shaft 167

OCTAVIA II 2004 ➤
Press on grooved ball bearing

Fitting position of grooved ball bearing:
The slot for the circlip points upwards -arrow A- and the shoulder
-arrow B- must point towards the 5th gear pinion.
Note
Position the thrust piece -VW 454- in such a way that the seal
-arrow C- of the bearing is not damaged.
– Determine the circlip ⇒ page 168 and install.
Determining the circlip

– Insert circlip -A- with a thickness of 1.86 mm in the slot of the
drive shaft and push upwards.
– Measure dimension between grooved ball bearing -B- and
positioned circlip -A- using a feeler gauge -C-.
– Remove the circlip used to take the measurement.
– Determine the first circlip required according to the table.
Note
Assign the circlips via the ⇒ Electronic catalogue of original parts .
The following circlips are available:

Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0,01 … 0,05 1,86 0,01 … 0,05
0,05 … 0,07 1,89 0,01 … 0,05
0,07 … 0,10 1,92 0,01 … 0,05
0,10 … 0,13 1,95 0,01 … 0,05
0,13 … 0,16 1,98 0,01 … 0,05
Pull out the cylindrical-roller bearing from the clutch housing

– When removing compress circlip -arrow- of the cylindrical-roll‐
er bearing with pliers -C-.
B - Interior extractor 30...37 mm , e.g. -Kukko 21/5-

OCTAVIA II 2004 ➤
Press the cylindrical-roller bearing into the clutch housing

– When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
– Remove pliers before the cylindrical-roller bearing is in fitting
position. The circlip must lock into the clutch housing slot.
1.2 Modifications in the area of the grooved

ball bearing/drive shaft
1.2.1 As of production date 04.06 up to pro‐

duction date 01.08.:
One washer above and one washer below the bearing pedestal
for the grooved ball bearing ⇒ Item 6 (page 166) .
Above the bearing pedestal:
Bearing pedestal Washer above the bearing pedestal

up to production date 03.06 Size “a” 10 mm. no
as of production date 04.06 Size “a” 10.7 mm. yes
up to production date 01.08
as of production date 02.08 Below the bearing pedestal: no
flattened part for the grooved ball
bearing
1. Drive shaft 169

OCTAVIA II 2004 ➤
Below the bearing pedestal -arrow-:

Slightly deeper as of production date 04.06 up to production date
01.08:
So that the washer below the grooved ball bearing
⇒ Item 6 (page 166) can be installed, the bearing pedestal for the
grooved ball bearing -arrow- is chamfered slightly deeper.
Below the bearing pedestal Washer below the bearing pedes‐

tal
up to production date 03.06 not chamfered. no
as of production date 04.06 chamfered slightly deeper. yes
up to production date 01.08
as of production date 02.08 Flattened part -B- for the grooved no
ball bearing -A- ⇒ page 170
1.2.2 As of production date 02.08.:

Flattened parts on the grooved ball bearing -A- and on the bearing
pedestal -B- of the gearbox housing
• If the flattened parts are present, a washer must not be inser‐
ted above or below the grooved ball bearing.

OCTAVIA II 2004 ➤
2 Output shaft gears 1 through 4
2.1 Disassembling and assembling output

shaft gears 1 through 4
♦ Thrust piece -MP3-411 (VW 454)-
♦ Pressure spindle -MP3-448 (VW 408A)-
♦ Pipe section -MP3-450 (VW 415A)-
♦ Pressure washer -MP3-460 (VW 512)-
♦ Thrust plate -MP3-467 (40-105)-
♦ Washer -MP6-415 (3260)-
♦ Bushing -T30010 (VW 540/1B)-
♦ Thrust piece -T30042 (2050)-
♦ Tapered-roller bearing extractor -V.A.G 1582-
♦ Gripper -V.A.G 1582/7-
Note
♦ If the output shaft or tapered-roller bearing is replaced, it is necessary to adjust the output shaft
⇒ page 182 .
♦ Replace both tapered-roller bearings together.
♦ A modified synchronization for 1st through 3rd gear is used in certain gearboxes ⇒ page 180 . The positions
8 to 12, 14 to 16, 18, 24, 26 to 28 and 30 are affected. Assign components via the ⇒ Electronic Catalogue
of Original Parts .
2. Output shaft gears 1 through 4 171

OCTAVIA II 2004 ➤
1 - Clutch housing
3 - Curved washer
❑ replace after removal
4 - Outer ring/tapered-roller
bearing
5 - Inner ring/tapered-roller
bearing
❑ pressing off
⇒ page 176
❑ pressing on
⇒ page 176
6 - Output shaft
❑ 1st to 4th gear
7 - Needle bearing
❑ for 2nd gear
9 - Synchronizer ring
❑ (Inner ring for 2nd gear)
❑ check for wear
⇒ page 176
❑ check pegs for wear
⇒ page 177
10 - Outer ring for 2nd gear
❑ position on the synchronizer ring -Pos. 9-
❑ replace if there are any traces of scoring or friction
11 - 2nd gear synchronizer ring
❑ check for wear ⇒ page 176
12 - Sliding sleeve with 1st and 2nd gear synchronizer body
❑ after removing the circlip -Pos. 13- press off with the 2nd gear sliding gear ⇒ page 175
❑ disassembling ⇒ page 177
❑ Assembling sliding sleeve/synchronizer body ⇒ page 177
13 - Circlip
14 - 1st gear synchronizer ring
❑ insert in such a way that the recesses lock into the arresters on the sliding sleeve Pos. 12
15 - Outer ring for 1st gear
❑ fit into synchronizer ring -Pos. 14-, fitting position ⇒ page 178

OCTAVIA II 2004 ➤
❑ (Inner ring for 1st gear)
17 - Needle bearing
❑ for 1st gear
19 - Thrust washers
❑ 1st and 4th gear
❑ 2 pieces
❑ Insert peg of thrust washer into the hole of the output shaft
20 - Washer
❑ holds the thrust washers pos. 19 in the correct position on the output shaft
21 - Needle bearing
❑ for 4th gear
23 - 4th gear synchronizer ring
24 - Sliding sleeve with 3rd and 4th gear synchronizer body
❑ after removing the circlip -Pos. 25- remove with the 4th gear sliding gear ⇒ page 175
❑ Fitting position of the sliding sleeve with synchronizer body ⇒ page 179
❑ Assembling sliding sleeve/synchronizer body ⇒ page 177 and ⇒ page 177
25 - Circlip
26 - 3rd gear synchronizer ring
27 - Outer ring for 3rd gear
❑ fit into synchronizer ring -Pos. 26-, fitting position ⇒ page 178
❑ (Inner ring for 3rd gear)
29 - Needle bearing
❑ for 3rd gear
31 - Inner ring/tapered-roller bearing

OCTAVIA II 2004 ➤
32 - Circlip
❑ determine ⇒ page 180 when replacing the tapered-roller bearing -Pos. 31- and the output shaft -Pos. 6-
❑ Determine thickness ⇒ page 182
Removing curved washer -A- from the output shaft
Press curved washer into the output shaft

– Press curved washer up to the dimension -a- into the output
shaft.
Dimension -a- = 2 mm + 0.5 mm.
Note
Press in curved washer max. 3 mm - not deeper.
Remove outer ring/tapered-roller bearing

B - Interior extractor 56 … 70 mm , e.g. -Kukko 21/8-

OCTAVIA II 2004 ➤
Press outer ring/tapered-roller bearing into the clutch housing

– Support the clutch housing with a pipe section -MP3-450 (VW
415A)- directly below the bearing support.
Pressing off inner ring/tapered-roller bearing

– First remove the circlip.
– Before fitting the extractor, position thrust piece -MP3-453- in
output shaft and lay pressure plate -MP3-467- over it.
Pressing off 3rd and 4th gear synchronizer body/sliding with slid‐
ing gear for 4th gear
Note
♦ If necessary, heat the 3rd and 4th gear synchronizer body with
a hot-air blower .
♦ After removing, inspect the running gear of the 4th gear sliding
gear for damage.
Sliding sleeve and synchronizer body for the 1st and 2nd gear
After removing the circlip jointly press off the 2nd gear sliding gear
and the sliding sleeve/synchronizer body.

OCTAVIA II 2004 ➤
Pressing off inner ring/tapered-roller bearing

Press on inner ring/tapered-roller bearing
Check 1st, 2nd and 3rd gear inner ring for wear
– Press the inner ring on the cone of the sliding gear and meas‐
ure clearance -a- with a feeler gauge.
Clearance -a- Fitting dimension Wear limit
1st, 2nd and 3rd 0,75…1,25 mm 0.3 mm
gear
Check 1st, 2nd and 3rd gear synchronizer rings for wear
– Press the synchronizer ring, outer ring and inner ring on the
cone of the sliding gear and measure clearance -a- with a
feeler gauge.
1st, 2nd and 3rd 1,2…1,8 mm 0.5 mm
gear

OCTAVIA II 2004 ➤
Fitting position of the outer ring, inner ring and 2nd gear syn‐
chronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
The angled lands -arrow 1- point towards the outer ring -B-.
– Position the outer ring -B-.
Lock the lands -arrows 2- in the recesses -arrows 3- of the sliding
gear.
– Position the synchronizer ring -C-.
Lock the recesses -arrows 4- in the lands -arrows 1- of the inner
ring -A-.
Disassembling and assembling the sliding sleeve and 1st, 2nd,

3rd and 4th gear synchronizer body
1- Spring
2- Arresters
3- Sliding sleeve
4- Synchronizer body
– Slide the sliding sleeve over the synchronizer body into fitting
position ⇒ page 177 or ⇒ page 179 .
The recesses for the arresters on the synchronizer body and the
sliding sleeve must be positioned above one another.
Assembly of the sliding sleeve/1st, 2nd, 3rd and 4th gear syn‐
chronizer body
The sliding sleeve is drawn over the synchronizer body.
– Insert arresters and mount springs with 120° offset. The an‐
gled end of the spring must grip into the hollow arrester.
Fitting position of the 1st and 2nd gear sliding sleeve/synchronizer

body
If applicable, the chamfer -arrow 1- on the sliding sleeve and the
narrow collar -arrow 2- of the synchronizer body point to the 1st
gear.

OCTAVIA II 2004 ➤
Press on the sliding sleeve and 1st and 2nd gear synchronizer
body
– Install circlip.
Fitting position of the 1st or 3rd gear outer ring

The pegs -arrows- point towards the synchronizer body/sliding
gear -A-.
Fitting position for synchronizer ring -A- (inner ring 1st or 3rd gear)
Lock the pegs -arrows 1- in the recesses -arrows 2- of the syn‐
chronizer ring -B-.
Fitting position 1st and 3rd gear sliding gear

The higher collar -A- points towards the 2nd or 4th gear -B-. The
recesses in the collar -arrows- lock into the pegs of the outer ring
⇒ page 178 .

OCTAVIA II 2004 ➤
Fitting position of the sliding sleeve/3rd and 4th gear synchronizer

body
The shoulder -arrow A- on the sliding sleeve and the wide collar
of the synchronizer body -arrow B- point to the 3rd gear.
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve
Checking 4th gear synchronizer ring for wear

– Press the synchronizer ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.
4th gear 1,0…1,7 mm 0.5 mm


OCTAVIA II 2004 ➤

– Determine the thickest circlip - that can be fitted - and insert.
Thickness (mm) Part number
1,79 02M 311 187 G
1,83 02M 311 187 F
1,86 02M 311 187 E
1,89 02M 311 187 D
1,92 02M 311 187 C
1,95 02M 311.187 B
1,98 02M 311 187 A
Remove outer ring/tapered-roller bearing from gearbox housing

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

– Position adjusting washer under outside ring.
– Support the gearbox housing with a pressure plate -T30042-
2.2 Synchronization for 1st through 3rd gear

is modified on certain gearboxes
These modification measures affect the following components:
♦ 1st through 3rd gear sliding gears
♦ Synchronizer rings for 1st through 3rd gear ⇒ page 181
♦ Sliding sleeve with 1st and 2nd gear synchronizer body
♦ Sliding sleeve with 3rd and 4th gear synchronizer body

OCTAVIA II 2004 ➤
Note
♦ Assign components via the ⇒ Electronic catalogue of original

parts .
♦ If components are not replaced, make sure that they are as‐
signed again to the original gear.
♦ Do not mix up synchronizer rings for 3rd gear with synchron‐
izer rings for 1st and 2nd gear (have different ∅).
♦ Check synchronizer rings for wear ⇒ page 181 or
⇒ page 182 .
Fitting position of the 1st through 3rd gear synchronizer rings

– Position inner ring -B- onto the sliding gear -A-.
– Position intermediate ring -C-.
• The pegs -1- of the intermediate ring must be inserted into the
recesses -2- of the sliding gear -A-.
– Position the synchronizer ring -D-.
• The drivers -3- of the inner ring -B- must be inserted into the
deeper openings -4- of the synchronizer ring -D-.
Position 1st and 3rd gear sliding gear with synchronizer rings as
follows onto the output shaft
– First the synchronizer ring -1- muss be inserted with the three
drivers -arrow A- into the recesses of the synchronizer body
-2-.
– Then position the intermediate ring and inner ring into the fit‐
ting position ⇒ page 181 .
– During installation, subsequently turn the 1st gear or 3rd gear
sliding gear -3- in such a way that the pegs -arrow B- on the
intermediate ring are inserted into the recesses -arrow C- of
the sliding gear.
Inspect the inner friction surface of the intermediate ring -2- for
wear
– First position the inner ring -1- and subsequently the inter‐
mediate ring -2- in the fitting position ⇒ page 181 onto the
sliding gear.
– Press the intermediate ring onto the cone of the inner ring and
measure the gap -a- (between sliding gear and intermediate
ring) at 3 points, offset by 120°, with a feeler gauge. Note the
mean value.
Clearance -a- Wear limit
1st, 2nd and 3rd gear 0.3 mm

OCTAVIA II 2004 ➤
Check the outer friction surface of the intermediate ring for wear
– Inspect synchronizer ring -arrow- on the inner friction surface
for scoring and radial bearing marks, replace if necessary.
– Position inner ring, intermediate ring and synchronizer ring in
fitting position ⇒ page 181 onto the sliding gear and “screw in”.
Note
“Screw in” means: Turn synchronizer rings by one revolution while

pressing on the rings simultaneously.
– Then measure the gap -a- at 3 points, offset by 120°, with a

feeler gauge . Note the mean value.
Clearance -a- Wear limit
1st, 2nd and 3rd gear 0.8 mm
Note
♦ When measuring, insert the feeler gauge in the area of the

synchronizer ring serration.
♦ When measuring, do not push the feeler gauge under the in‐
termediate ring, only measure the gap -a- between sliding gear
and synchronizer ring.
♦ Replace the inner ring, intermediate ring and synchronizer ring
together for the relevant gear ⇒ Electronic Catalogue of Orig‐
inal Parts .
2.3 Setting output shaft gears 1 through 4

♦ Washer -MP6-415 (3260)-
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Assembly device -T30069 (VW 792)-
(Determine adjusting washer for output shaft)
The output shaft must be re-set when the following components
are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft gears 1 through 4
♦ Tapered-roller bearing for output shaft
Requirements:
• Sealing surfaces of clutch and gearbox housing must be re‐
moved of sealant residues.

OCTAVIA II 2004 ➤
• During the measurement, only install the output shaft to be

measured.
– Press outer ring/tapered-roller bearing with a 1.70 mm thick
adjusting washer into the gearbox housing. While doing so
support the gearbox housing with a pressure plate -T30042-
– Insert complete output shaft gears 1 through 4 into the clutch
housing.
– Fit on gearbox housing and tighten screws -A- and -B- cross‐
wise with tightening torque.
– Mount the measuring tools and fasten with screw -arrow- to

the clutch housing.
– Set dial gauge (3 mm measuring range) to “0” with a 1 mm
bias.
– Slacken fixing screws of clutch housing/gearbox housing
crosswise, until the screws release the gearbox housing or the
output shaft.
– Read off measured value on dial gauge and note (example:
0,14 mm).
Note
If no measured value is displayed on the dial gauge when loos‐

ening the fixing screws of the clutch housing/gearbox housing,
install the adjusting washer 1.95 mm or if necessary the adjusting
washer 2.20 mm for the measurement.
2.3.1 Determine the adjusting washer

The prescribed bearing preload is reached by removing the es‐
tablished measured value (0.14 mm) from the inserted adjusting
washer (1.70 mm) and by adding a constant compression value
(0.20 mm).

OCTAVIA II 2004 ➤
Example:
inserted washer 1.70 mm
- measured value 0.14 mm
+ compression (constant value) 0.20 mm
Thickness of the adjusting washer 1.76 mm
– Determine thickness of the adjusting washer according to the
table ⇒ page 184 .
– Remove the gearbox housing and pull the outer ring/tapered-
roller bearing out of the gearbox housing.
– Remove the inserted adjusting washer (1.70 mm thick) from
Adjusting washer table
1,45 084 409 383 AG
1,50 084 409 383 AH
1,55 084 409 383 AJ
1,60 084 409 383 AK
1,65 084 409 383 AL
1,70 084 409 383 AM
1,75 084 409 383 AN
1,80 084 409 383 AP
1,85 084 409 383 AQ
1,90 084 409 383 AR
1,95 084 409 383 AS
2,00 084 409 383 AT
2,05 084 409 383 BA
2,10 084 409 383 BB
2,15 084 409 383 BC
2,20 084 409 383 BD
2,25 084 409 383 BE
Different tolerances allow to select the required thickness for each
– Press in outer ring/tapered-roller bearing with the determined

adjusting washer (in the example: 1.75 mm). While doing so
2.3.2 Control measurement

• Determined adjusting washer fitted.

OCTAVIA II 2004 ➤
– Mount the measuring tools and fasten with screw -arrow- to

the clutch housing.
bias.
output shaft.
– The dial gauge must indicate a value of 0.15 mm to 0.25 mm
if the adjusting washer has been correctly chosen.

OCTAVIA II 2004 ➤
3 Output shaft 5th/6th gear/reverse

gear
♦ Pipe -MP3-408 (VW 412)-
♦ Base -MP3-410 (VW 434)-
♦ Drive bushing -MP3-412 (VW 455)-
♦ Base -MP3-413 (VW 510)-
♦ Pipe -MP3-423 (VW 407)-
♦ Drift pin -MP3-448 (VW 408)-
♦ Knock-in bushing -MP3-450 (VW 415A)-
♦ Alignment rails -MP3-457 (VW 457) -
♦ Knock-in bushing -MP3-461 (VW 519)-
♦ Base -MP3-467 (40-105)-
♦ Thrust piece - MP3-4014 (VW 432)-
♦ Base -MP6-415 (3260)-
♦ Gearbox mount -T30108-
♦ Pipe -T30055 (3296)-
♦ Thrust piece -T30091 (40 - 202) -
♦ Separating device , e.g. -Kukko 17/2-

OCTAVIA II 2004 ➤
3.1 Disassembling and assembling output shaft 5th/6th and reverse gear
Note
♦ If the output shaft or tapered-roller bearing is replaced, it is necessary to adjust the output shaft
⇒ page 193 .
1 - Clutch housing
2 - Base
bearing
❑ pressing on
⇒ page 189
bearing
❑ pressing on
⇒ page 192
5 - Output shaft
❑ 5th/6th and reverse
gear
6 - Reverse gear synchronizer
body
❑ pressing off
⇒ page 190
⇒ page 190
❑ pressing on
⇒ page 190
7 - Circlip
8 - Reverse gear sliding sleeve
❑ with synchronizer ring
9 - Needle bearing (polygon
bearing)
❑ for reverse gear sliding
gear
11 - Bushing
❑ pressing off with reverse gear sliding gear ⇒ page 189
❑ Fitting position: broad collar of bushing points to the reverse gear sliding gear
12 - Circlip
13 - Needle bearing (polygon bearing)
❑ for 6th gear
3. Output shaft 5th/6th gear/reverse gear 187

OCTAVIA II 2004 ➤

16 - Sliding sleeve with 5th and 6th gear synchronizer body
❑ after removing the circlip -Pos. 17- press off with the 6th gear sliding gear ⇒ page 189
❑ Assembling sliding sleeve/synchronizer body ⇒ page 191 and ⇒ page 191
17 - Circlip
❑ for 5th gear
21 - Inner ring/tapered-roller bearing
22 - Circlip
❑ determine ⇒ page 192 when replacing the tapered-roller bearing -Pos. 21- and the output shaft -Pos. 5-
❑ Determine thickness ⇒ page 194
26 - Spring
27 - Sliding sleeve
28 - Synchronizer body
29 - Arresters (3 pieces)
Remove outer ring/tapered-roller bearing

Note
After pulling out the washer check for damage, if necessary re‐
place.

OCTAVIA II 2004 ➤

– Position washer under outside ring.
– Support the clutch housing with a pressure plate -T30091- di‐
rectly below the bearing support.
Removing inner ring/tapered-roller bearing

– Before fitting the extractor position thrust piece -MP3-453- and
pressure plate -MP3-467- on output shaft.
Pressing off 5th and 6th gear synchronizer body/sliding with slid‐
ing gear for 6th gear
Pressing off bushing -A- with reverse gear sliding gear


OCTAVIA II 2004 ➤
Pressing off reverse gear synchronizer body


– Before fitting the extractor, position pressure plate -MP3-410-
on the output shaft.
Fitting position of reverse gear synchronizer body

The stop -arrow A- for the reverse gear sliding sleeve points to‐
wards the output shaft serration -arrow B-.
Pressing on reverse gear synchronizer body


OCTAVIA II 2004 ➤
Pressing on bushing -A-

Fitting position: Broad collar points towards the reverse gear slid‐
ing gear.
Check 5th and 6th gear synchronizer ring for wear

– Press the synchronizer ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.
5th and 6th gear 1,0…1,7 mm 0.5 mm
Disassembling and assembling the sliding sleeve and 5th and 6th
gear synchronizer body
1- Spring
2- Arresters
3- Sliding sleeve
4- Synchronizer body
– Slide the sliding sleeve over the synchronizer body.
The recesses for the arresters on the synchronizer body and the
sliding sleeve must be positioned above one another.
Assembly of the sliding sleeve/5th and 6th gear synchronizer

body
The sliding sleeve is drawn over the synchronizer body.
– Insert arresters and mount springs with 120° offset. The an‐
gled end of the spring must grip into the hollow arrester.

OCTAVIA II 2004 ➤
Press on the sliding sleeve and 5th and 6th gear synchronizer
body


– Determine the thickest circlip - that can be fitted - and insert.
1,79 02M 311 187 G
1,83 02M 311 187 F
1,86 02M 311 187 E
1,89 02M 311 187 D
1,92 02M 311 187 C
1,95 02M 311.187 B
1,98 02M 311 187 A

OCTAVIA II 2004 ➤


– Support the gearbox housing with a pressure plate -T30042-
3.2 Setting output shaft 5th/6th and reverse

gear
♦ Base -MP6-415 (3260)-
♦ Pipe -MP3-423 (VW 407)-
♦ Gearbox mount -T30108-
♦ Assembly device -T30069 (VW 792)-
The output shaft must be re-set when the following components
are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft 5th/6th gear/reverse gear
♦ Tapered-roller bearing for output shaft
Setting overview ⇒ page 210
Requirements:
• Sealing surfaces of clutch and gearbox housing must be re‐
moved of sealant residues.
• During the measurement, only install the output shaft to be
measured.

OCTAVIA II 2004 ➤
– Press outer ring/tapered-roller bearing with a 1.70 mm thick

adjusting washer into the gearbox housing. While doing so
– Insert complete output shaft 5th/6th gear and reverse gear into
the clutch housing.
– Fit on gearbox housing and tighten screws -A- and -B- cross‐
wise with tightening torque.
– Mount the measuring tools. Fit washers with a total thickness

of 8 mm at the fixing screws -arrow- for assembly device -
T30069- onto the clutch housing.
bias.
output shaft.
– Read off measured value on dial gauge and note (example:
0.25 mm).
Note
If no measured value is displayed on the dial gauge when loos‐

ening the fixing screws of the clutch housing/gearbox housing,
install the adjusting washer 1.95 mm or if necessary the adjusting
washer 2.20 mm for the measurement.

The prescribed bearing preload is reached by removing the es‐
tablished measured value (0,25 mm) from the inserted adjusting
washer (1.70 mm) and by adding a constant compression value
(0.20 mm).
Example:
inserted washer 1.70 mm

OCTAVIA II 2004 ➤
- measured value 0.25 mm

+ pressure (const. value) 0.20 mm
Thickness of the adjusting washer 1.65 mm
– Determine thickness of the adjusting washer according to the
table ⇒ page 195 .
– Remove the gearbox housing and pull the outer ring/tapered-
roller bearing out of the gearbox housing.
– Remove the inserted adjusting washer (1.70 mm thick) from
Adjusting washer table
1,50 084 409 383 AH
1,55 084 409 383 AJ
1,60 084 409 383 AK
1,65 084 409 383 AL
1,70 084 409 383 AM
1,75 084 409 383 AN
1,80 084 409 383 AP
1,85 084 409 383 AQ
1,90 084 409 383 AR
1,95 084 409 383 AS
2,00 084 409 383 AT
2,05 084 409 383 BA
2,10 084 409 383 BB
2,15 084 409 383 BC
2,20 084 409 383 BD
2,25 084 409 383 BE
– Press in outer ring/tapered-roller bearing with the determined

adjusting washer (in the example: 1,65 mm). While doing so
3.2.2 Control measurement

• Determined adjusting washer fitted.

OCTAVIA II 2004 ➤
– Mount the measuring tools. Fit washers with a total thickness

of 8 mm at the fixing screws -arrow- for assembly device -
T30069- onto the clutch housing.
bias.
output shaft.
– The dial gauge must indicate a value of 0.15 mm to 0.25 mm
if the adjusting washer has been correctly chosen.

OCTAVIA II 2004 ➤
39 – Final drive, differential gear

1 Replacing gasket rings for flange
shaft or rigid shaft with gearbox in‐
stalled
1.1 Replacing the left flange shaft gasket

ring (front-wheel drive and four-wheel
drive)
♦ Extraction hook -MP3-419/37 (VW 771/37)-
♦ Catch pan
1.1.1 Removing
– Remove front left wheel ⇒ Chassis ⇒ Rep. Gr. 44 and raise
vehicle.
– Remove the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Turn steering to full left lock.
– Remove left drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Position the catch pan under the gearbox.
– Release the fixing screw for the flange shaft, to this end insert
two screws in the flange and counterhold the flange shaft using
an assembly lever.
– Remove the flange shaft with pressure spring.
1. Replacing gasket rings for flange shaft or rigid shaft with gearbox installed 197
OCTAVIA II 2004 ➤
– Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419- and -MP3-419/37- .
1.1.2 Install
– Drive the new seal ring in up to the stop, do not twist the seal
ring.
– Insert the flange shaft.
– Secure the flange shaft with the conical screw and tighten with
tightening torque.
– Install left drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Inspecting gear oil ⇒ page 100 .
– Install the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Install wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
Tightening torque
Component Nm
Flange shaft on gearbox (conical screw) ⇒ page 117
1.2 Replacing the right rigid shaft gasket

ring (front-wheel drive)
♦ Catch pan
1.2.1 Removing
198 Rep. Gr.39 - Final drive, differential gear

OCTAVIA II 2004 ➤
– Remove right drive shaft -A- ⇒ Chassis ⇒ Rep. Gr. 40 .

– Unscrew -arrows- intermediate shaft -B- from bracket -D- and
pull off from the rigid shaft of the gearbox.
– Release fixing screw for rigid shaft.
– Remove the rigid shaft with pressure spring.
– Lever out gasket ring with assembly lever.
1.2.2 Install
ring.
– Replace the O-ring on the rigid shaft.
– Insert rigid shaft.
– Secure the rigid shaft with the conical screw and tighten with
tightening torque.
– Grease the spline on the rigid shaft with grease for plug ser‐
ration of clutch disc -G 000 100- .
– Guide the intermediate shaft -B- through the bracket -C- onto
the rigid shaft of the gearbox.
– Tighten intermediate shaft to bracket -arrows- ⇒ Chassis ⇒
Rep. Gr. 40 .
– Install right drive shaft -A- ⇒ Chassis ⇒ Rep. Gr. 40 .
Tightening torque
Component Nm
Rigid shaft on gearbox (conical screw) ⇒ page 119
1.3 Replacing the right flange shaft gasket

ring (front-wheel drive)
♦ Catch pan
1.3.1 Removing
OCTAVIA II 2004 ➤
– Remove heat shield for right drive shaft (if present) from the
engine -arrows-.
– Unscrew right drive shaft from the flange shaft -A- of the gear‐
box ⇒ Chassis ⇒ Rep. Gr. 40 .
– Tie up the drive shaft as far as possible. Avoid damaging the
paintwork on the drive shaft during this operation.
– Release the fixing screw for the right flange shaft, to this end
insert two screws in the flange and counterhold the flange
shaft using an assembly lever.
– Remove the flange shaft with pressure spring.
– Lever out gasket ring with assembly lever.
1.3.2 Install
ring.
– Insert the flange shaft.
– Secure the flange shaft with the conical screw and tighten with
tightening torque.
– Attach the right drive shaft to the flange shaft of the gearbox
– Install heat shield for right drive shaft (if present) at the engine.
Tightening torques
Component Nm
Heat shield of drive shaft to engine ⇒ page 99
1.4 Replacing the right flange shaft gasket

ring (four-wheel drive)
♦ Ejection lever -MP3-418 (VW 681)-
♦ Extractor -T10037-

OCTAVIA II 2004 ➤

♦ Catch pan
1.4.1 Removing
– Loosen the front right wheel bolts.
– Detach the right front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– On vehicles with particle filter if necessary remove the bracket
for the particle filter ⇒ Engine ⇒ Rep. Gr. 26 .
insert -T10107A- .
Note

flange.
– Remove gasket ring with ejection lever -MP3-418- .
1.4.2 Install
– Lightly oil new gasket ring at outer surface.
OCTAVIA II 2004 ➤
– Drive in the new gasket ring with thrust piece -T10049- up to

the stop, do not twist the new gasket ring.
– Carefully drive in flange shaft (slowly turn flange shaft).
sert -T10107A- .
plug -B-.
– On vehicles with particle filter install the bracket for the particle
filter, if it was removed ⇒ Engine ⇒ Rep. Gr. 26 .
– Install right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Install heat shield for drive shaft -arrows-, if it was removed.

Gr. 66 .
– Attach the right front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
Tightening torques
Component Nm
box
1.5 Replacing gasket rings between angle

gearbox and manual gearbox (four-
wheel drive)
♦ Extraction hook -T20143-
♦ Catch pan

OCTAVIA II 2004 ➤
1.5.1 Replace gasket ring at angle gearbox

Removing
– Remove angle gearbox ⇒ page 101 .
– Pull out gasket ring for angle gearbox with extraction hook -
T20143- .
Install

– Install angle gearbox ⇒ page 106 .
– Inspecting oil level in the angle gearbox ⇒ page 109 .
1.5.2 Replace gasket ring at manual gearbox

Removing
– Pull out gasket ring for manual gearbox with extraction hook -
T20143- .
Install
– Inspect the gear oil in the manual gearbox ⇒ page 100 .
OCTAVIA II 2004 ➤
1.6 Replacing the needle bearing (polygon

bearing) and gasket ring on right flange
shaft (four-wheel drive)
♦ Assembly device -MP6-414 (3253)-
♦ Tensioning device -T10047-
♦ Catch pan
1.6.1 Removing
– Loosen the front right wheel bolts.
– Detach the right front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– On vehicles with particle filter if necessary remove the bracket
for the particle filter ⇒ Engine ⇒ Rep. Gr. 26 .
insert -T10107A- .

OCTAVIA II 2004 ➤
Note

flange.
Mount tensioning device -T10047- as described further on:

– Assemble both parts of the tensioning device , so that the
markings -B- point towards each other.
– The shoulders -arrows- must be under the bearing.
– Screw together both halves up to the stop.
– Remove circlip -A- for the needle bearing.

– In order to avoid damaging the contact surface of the needle
bearing on the shaft, turn the shaft during the pressing proce‐
dure -arrow-.
– Remove gasket ring -A- from the slot -arrow-.
1.6.2 Install
– The installation occurs in reverse order, while paying attention
to the following.
OCTAVIA II 2004 ➤
– Moisten gasket ring -2- with gear oil.

– Insert gasket ring -A- into the slot -arrow-.
– Mount tensioning device -T10047- ⇒ page 205 .
– In order to avoid damaging the contact surface of the needle

bearing on the shaft, turn the shaft during the pressing proce‐
dure -arrow-.
– Secure bearing with new circlip ⇒ Electronic Catalogue of
Original Parts .
– Carefully drive in flange shaft (slowly turn flange shaft).
sert -T10107A- .
plug -B-.
– On vehicles with particle filter install the bracket for the particle
filter, if it was removed ⇒ Engine ⇒ Rep. Gr. 26 .
– Install right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Install heat shield for drive shaft -arrows-, if it was removed.

Gr. 66 .
– Attach the right front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
Tightening torques
Component Nm
box

OCTAVIA II 2004 ➤
1.7 Replacing the angle gearbox output

flange gasket ring (four-wheel drive)
♦ Thrust plate -MP3-467 (40-105)-
♦ Gearbox mount -T30097 (T10108) -
♦ Stop plate -T30097/1 (T10108/1)-
♦ Two-arm extractor , e.g. -Kukko 20/10-
♦ Three armed extractor e.g. -Kukko 45-2-
♦ Catch pan
♦ Locking agent -D 000 600-
The gasket ring for the angle gearbox output flange can only be
replaced with the angle gearbox removed.
1.7.1 Removing
– Screw angle gearbox on gearbox mount - T30097- .
A - Place nut M12 x 10 (8 pieces) between angle gearbox and
gearbox mount -T30097- .
– Remove oil drain plug -A- from angle gearbox.

– Drain oil out of angle gearbox.
– Install oil drain plug -A- and tighten to tightening torque.
OCTAVIA II 2004 ➤
– Lock the output flange for angle gearbox with stop plate -
T30097/1 (T10108/1)- and two screws M10 x 30 -arrows-.
– Unscrew nut for output flange (always replace nut ⇒ Electronic
Catalogue of Original Parts ).
A - socket wrench insert SW 36
– Detach output flange with three armed extractor -A- and thrust
plate -MP3-467- .
A - Three armed extractor e.g. -Kukko 45-2 -
Note
When pulling off the output flange the inner ring/tapered-roller

bearing remains on the output flange and must be removed from
it.
– Remove inner ring/tapered-roller bearing with tapered-roller

bearing extractor -V.A.G 1582- and gripper - V.A.G 1582/6-
from output flange.
– Pull out seal ring for angle gearbox output flange with Multi-
purpose tool -MP3-419- .
– Clean the thread at the shank bevel gear to remove locking
agent residues.
1.7.2 Install
– Swivel angle gearbox in such a way that the cover -1- points
upwards.
– Place inner ring/tapered-roller bearing in the angle gearbox.

OCTAVIA II 2004 ➤
– Insert output flange with two-arm extractor -A-, pipe section -

MP3-414- and pressure plate - MP3-467- , while doing so
position the pull-off hooks of the extractor on the bottom side
of the housing.
A - Two-arm extractor , e.g. -Kukko 20/10 -
– Insert new hexagon nut with locking agent -D 000 600- and
tighten to the prescribed tightening torque.
A - socket wrench insert SW 36
– After installing, check gear oil level in the angle gearbox and
top up oil ⇒ page 109 .
Tightening torques
Component Nm
Oil drain plug 60
Nut for output flange1 480
1) Always replace nut ⇒ Electronic Catalogue of Original Parts
OCTAVIA II 2004 ➤
2 Setting overview
Note
When working on the gearbox it is only necessary to re-set the

output shaft gears 1 through 4, output shaft 5th/6th gear and re‐
verse gear or differential gear if parts were replaced that directly
affect the setting of the gearbox. To avoid unnecessary settings,
refer to the following table:
Set:
Output shaft Output shaft Differential
gears 1 5th/6th and gear
through 4 reverse gear ⇒ page 220
⇒ page 182 ⇒ page 193
Replaced part: Gearbox housing x x x
Clutch housing x x x
Output shaft gears 1 through 4 x
Output shaft 5th/6th gear/reverse x
gear
Differential gear housing x
Tapered-roller bearing for output x
shaft gears 1 through 4
Tapered-roller bearing for output x
shaft 5th/6th and reverse gear
Tapered-roller bearings for differ‐ x
ential gears.

OCTAVIA II 2004 ➤
3 Differential gear
3.1 Summary of components - Front-wheel-drive
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ When replacing the tapered-roller bearings, the differential gear housing, the gearbox housing or the clutch
housing, adjust the differential ⇒ page 220 .
1 - Gearbox housing
❑ Determine thickness
⇒ page 220
bearing
bearing
❑ pressing on
⇒ page 217
5 - Differential gear housing
❑ with riveted pinion for fi‐
nal drive
❑ Support -arrow- for the
right tapered-roller
bearing with insert for
right flange shaft ap‐
prox. 28 mm longer
Parts
bearing
❑ Gearbox with right rigid
shaft: pressing on
⇒ page 218
❑ Gearbox with right
flange shaft: pressing
on ⇒ page 218
8 - Washer
3. Differential gear 211

OCTAVIA II 2004 ➤
9 - Clutch housing
10 - O-ring
11 - Cap
❑ can be removed from the rigid shaft pos. 13 or pressed on by hand
12 - 33 Nm
❑ screw into threaded piece Pos. 26
13 - Rigid shaft
❑ on gearboxes as of production date 01 11 4 replaced by flange shaft
14 - Sealing ring
❑ for rigid shaft up to production date 31 10 4
❑ Assignment ⇒ Electronic Catalogue of Original Parts replaces as of production date 01 11 4 the rigid
shaft Pos. 13
16 - Cap
❑ release with screwdriver alternatively from the flange shaft pos. 15
17 - Sealing ring
❑ for flange shaft as of production date 01 11 4 Pos.15
18 - Pressure spring for flange or rigid shaft
❑ rear flange or rigid shaft fitted
19 - Thrust washer
❑ Fitting position: Collar to pressure spring, leg (if present) to conical ring
20 - Conical ring
❑ with slots (if present) for thrust washer catch
❑ Fitting position: Cone towards differential gear housing
21 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft or rigid shaft is
removed
22 - large differential bevel gear
23 - Differential bevel gear shaft
❑ drive out with drift
24 - Tensioning sleeve
❑ to secure the differential bevel gear shaft
25 - small differential bevel gear
26 - Threaded part

OCTAVIA II 2004 ➤
27 - Stop disc compound

❑ when installing moisten with gearbox oil
28 - Cap
❑ release with screwdriver alternatively from the flange shaft pos. 29
❑ Fitting position: Recess points away from the threaded holes in the flange shaft
29 - Flange shaft
30 - Sealing ring
❑ for flange shaft

OCTAVIA II 2004 ➤
3.2 Summary of components - Four-wheel drive
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ When replacing the tapered-roller bearings, the differential gear housing, the gearbox housing or the clutch
housing, adjust the differential ⇒ page 220 .
1 - Gearbox housing
❑ Determine thickness
⇒ page 220
bearing
bearing
❑ pressing on
⇒ page 217
5 - Differential gear housing
❑ with riveted pinion for fi‐
nal drive
bearing
❑ pressing on
⇒ page 218
bearing
8 - Washer
❑ Fitting position: the
shoulder on the inside
diameter points towards
the angular gearbox
Pos. 18
9 - Clutch housing
10 - Sealing ring
❑ between manual gearbox and angle gearbox
❑ pull out using ejection lever -MP3-418- or ejection lever -T20143/2-
❑ on disassembled gearbox it can be driven in with pressure plate -T40007 - up to the stop
11 - Sealing ring
❑ for right flange shaft
❑ diameter of left and right differ

OCTAVIA II 2004 ➤
❑ replace with installed manual gearbox with angle gearbox ⇒ page 200
❑ 4 pieces
13 - 33 Nm
❑ screw into threaded piece Pos. 24
15 - Sealing ring
❑ to replace, remove the needle bearings (polygon bearing ) pos. 16
17 - Circlip
18 - Angle gearbox
❑ Removing and installing with gearbox fitted ⇒ page 101
❑ Removing and installing with gearbox removed ⇒ page 123
19 - Sealing ring
❑ between angle gearbox and manual gearbox
❑ replacing with angle gearbox removed ⇒ page 203
20 - large differential bevel gear
21 - Differential bevel gear shaft
22 - Tensioning sleeve
❑ to secure the differential bevel gear shaft
❑ drive in the new tensioning sleeve ⇒ page 219 flush
23 - small differential bevel gear
24 - Threaded part
25 - Stop disc compound
❑ insert with gear oil
26 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
27 - Conical ring
❑ with slots (if present) for thrust washer catch
❑ Fitting position: Cone towards differential gear housing
28 - Thrust washer
❑ Fitting position: Collar to pressure spring, leg (if present) to conical ring
29 - Pressure spring for left flange shaft
❑ fitted behind left flange shaft

OCTAVIA II 2004 ➤
30 - Flange shaft left

31 - Sealing ring
❑ for left flange shaft
❑ diameter of left and right differ
3.3 Disassembling and assembling differen‐

tial gear
♦ Pipe section -MP3-450 (VW 415A)-
♦ Thrust plate -MP3-467 (40-105)-
♦ Pipe -MP6-419 (3259)-
♦ Pipe -T30019 (3345)-
♦ Thrust plate -T30045 (3005)-
♦ Pipe -T30055 (3296)-
♦ Separating device 12...75 mm , e.g. - Kukko 17/1-
♦ Extractor , e.g. -Kukko 18/1-
♦ Interior extractor 46...58 mm e.g. -Kukko 21/7-
Remove outer ring/tapered-roller bearing from clutch housing
Note
♦ Tighten the interior extractor -B- between the outer ring/ta‐

pered-roller bearing and the washer.
♦ After pulling out the washer check for damage, if necessary
replace.

OCTAVIA II 2004 ➤

– First insert the washer.
Note
Pay attention to the fitting position of the washer, the shoulder on

the inside diameter points towards the gasket ring in the clutch
housing.

B - Thrust plate -MP3-467 (40-105)-
– Tighten the extractor -A- in the area of the flattened sides of
the differential gear housing below the inner ring.
Note
When pulling off the inner ring make sure the hooks do not bend
outwards, if necessary tighten screw.


OCTAVIA II 2004 ➤
Gearbox with right rigid shaft: Press on inner ring/tapered-roller

bearing
– Place pressure plate -MP3-459- with small external diameter
onto the inner ring/tapered-roller bearing.
It must be possible to rotate the cage with the taper rollers freely
when pressing on.
Gearbox with right flange shaft: Press on inner ring/tapered-roller

bearing
It must be possible to rotate the cage with the taper rollers freely
when pressing on.
Four-wheel drive: Press on inner ring/tapered-roller bearing

– Place sleeve from the assembly device -MP5-402- with the
opening -arrow- (large internal diameter) onto the inner ring/
tapered-roller bearing.


OCTAVIA II 2004 ➤

– Support the gearbox housing with a pipe -T30019- directly be‐
low the bearing support.
Remove and install the tensioning sleeve for differential bevel

gear shaft
Removing
– Cover inner ring/tapered-roller bearing to avoid any possible
damage and swarf.
– Drive out tensioning sleeve with a chisel, position the chisel in
the circular slot.
Install
– Drive into the differential gear housing up to the stop.
Four-wheel drive: Remove differential bevel gear shaft and ten‐

sioning sleeve for differential bevel gear shaft
– First drive in the tensioning sleeve -1- into the differential bevel
gear shaft -2- flush.
– Then position the differential with the tensioning sleeve
-arrow- pointing towards the pipe section -MP3-451- under the
press.
– Then press out the differential bevel gear shaft.
Note
If necessary remove the cut parts of the tensioning sleeve from

the differential gear housing.
Four-wheel drive: Install tensioning sleeve

– Drive in the new tensioning sleeve -arrow- flush to the differ‐
ential gear housing using a drift -1-.

OCTAVIA II 2004 ➤
Install 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 both small differential bevel gears into posi‐
tion with a 180° offset.
– Push in the differential bevel gear shaft -arrow A- up to the first
small differential bevel gear.
– Insert the threaded parts -arrows B- in the large differential
bevel gears.
Fitting position: Heel towards the large differential bevel gears
– Drive in the differential bevel gear shaft up to end position and
secure with tensioning sleeve.
3.4 Adjusting the differential gear

♦ Gauge block plate -MP3-405/17 (VW 385/17)-
♦ Pipe -MP6-419 (3259)-
♦ Pipe -T30019 (3345)-
♦ Thrust plate -T30045 (3005)-
♦ Interior extractor 46...58 mm e.g. -Kukko 21/7-
The differential gear must be re-set when the following compo‐
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Differential gear housing
♦ Tapered-roller bearings of the differential gear
Setting overview ⇒ page 210 .
– Press the outer ring/tapered-roller bearing with washer in the
clutch housing.
Note
Pay attention to the fitting position of the washer, the shoulder on

the inside diameter points towards the gasket ring in the clutch
housing.

OCTAVIA II 2004 ➤
– Press outer ring/tapered-roller bearing without adjusting

washer into the gearbox housing.
– Insert the differential gear in the clutch housing.
– Position the gearbox housing and tighten 5 screws to the given
tightening torque ⇒ page 117 .
– Press differential gear towards the clutch housing while simul‐
taneously turning eight times.
– Press differential gear towards the gearbox housing while si‐
multaneously turning eight times.
– Set the dial gauge to 0 with 1 mm preload on “0”.

A - Dial gauge extension 30 mm
– Move the differential gear up and down, read off and write
down the clearance on the dial gauge (example: 0.70 mm).

The prescribed bearing preload is reached by adding to the es‐
tablished measured value a constant compression value (0,25
mm).
Example:
measured value 0.70 mm
+ compression (constant value) 0.25 mm
= Thickness of the adjusting washer 0.95 mm
– Remove the gearbox housing.

OCTAVIA II 2004 ➤
– Remove outer ring/tapered-roller bearing from gearbox hous‐

ing.
– Insert an adjusting washer of the correct thickness.
The following adjusting washers are available:
0,65 02B 409 210
0,70 02B 409 210 A
0,75 02B 409 210 B
0,80 02B 409 210 C
0,85 02B 409 210 D
0,90 02B 409 210 E
0,95 02B 409 210 F
1,00 02B 409 210 G
1,05 02B 409 210 H
1,10 02B 409 210 J
1,15 02B 409 210 K
1,20 02B 409 210 L
1,25 02B 409 210 M
If the measured washer thickness is greater than the one listed in
the table, 2 washers corresponding to the measured value may
be fitted. First insert the thicker adjusting washer.
– Press outer ring in again and tighten the gearbox housing with
tightening torque ⇒ page 117 .

OCTAVIA II 2004 ➤
4 Removing and installing propshaft
4.1 Removing and installing “two-piece”

propshaft
♦ Engine and gearbox jack e.g. -V.A.G 1383A -
Note
♦ The two-piece propshaft is installed until 27.05.07. The front

propshaft pipe can be separated from rear propshaft pipe.
♦ Work on the propshaft should be carried out on a two-pillar lift
platform.
♦ Before the removal, mark the position of all parts to each other.
Carry out the installation again in the same position, otherwise
the imbalance is too great, damages to the bearing and hum‐
ming noises could occur.
♦ Do not bend the propshaft, only store extended and transport.
4.1.1 Removing
– Removing the whole exhaust gas system ⇒ Engine ⇒ Rep.
Gr. 26 .
– Support propshaft with engine and gearbox jack e.g. -V.A.G
1383A- (as an aid, e.g. use a wooden wedge)
– Remove heat shield -2-, to do so release the screws -1-.
– After removing the heat shield screw on again by hand the
intermediate bearing of the propshaft with the screws -1-.
– Unscrew propshaft from angle gearbox -arrows-.
4. Removing and installing propshaft 223

OCTAVIA II 2004 ➤

Note
After unscrewing the fixing screws for the pendulum support at

the gearbox, the engine/gearbox unit swivels slightly towards the
front (direction front). Make sure that the gasket ring in the flange
of the propshaft is not damaged.
– Check, if the markings of the CV joint/propshaft

-arrows A and B- are present. If not, mark them with colours.
– Flange off the front propshaft pipe from the rear propshaft pipe
-arrows-.
– Push the front propshaft pipe to the front and swivel out the
flange of the rear propshaft pipe.
Note
When swivelling out make sure that the front propshaft pipe is
inclined as little as possible to the bottom.
– Carefully pull off the front propshaft pipe from the centering
stud.
Note
The gasket ring -arrow- in the flange of the propshaft must not be
damaged.
– Pull off propshaft horizontally from centering stud.

– Swivel down the front propshaft pipe and remove.

OCTAVIA II 2004 ➤
– Check, if a marking (colour point) is present on the flexible

disk/oscillation damper and at the flange on the Haldex cou‐
pling -arrows-. If not, mark the position of the flexible disk and
the flange on the Haldex coupling to each other -arrows-.
– Unscrew rear propshaft pipe with flexible disk and oscillation

damper from rear final drive -arrows-.
– Unscrew intermediate bearing of propshaft from the vehicle.
– Carefully pull off the rear propshaft pipe from the centering
stud.
Note
♦ Do not tilt propshaft when removing, pull off horizontally from

the centering stud.
♦ The gasket ring in the centering bush -arrow- must not be
damaged.
The flexible disk and oscillation damper cannot be separated.
4.1.2 Install
following points:
When re-installing, fit all parts of the propshaft marked to each
other in the same position.
The gasket rings -arrow- in the flanges of the propshaft must not
be damaged when removing and installing. In case of damaged
gasket rings the propshaft must be replaced.
– Push propshaft horizontally onto the respective centering
studs.
Fitting position:
Three protruding bushings at the angle gearbox flange or the
Haldex coupling flange and propshaft flange grip into the location
holes of the flexible disks.

OCTAVIA II 2004 ➤
– Install the propshaft on the flange of the Haldex coupling and

on the flange of the angle gearbox in such a way that the
markings -arrows- are on the same line.
Observe fitting location of the different collar screws.

Collar screw with Fitting location
small collar -arrow A- Propshaft on front final drive
-A-
large collar -arrow B- Propshaft on rear final drive
-B-
– Align intermediate bearing in its elongated holes in such a way
that the propshaft or the intermediate bearing is not under ten‐
sion.
– Only screw down intermediate bearing after tightening the
propshaft.
When screwing the heat shield -2- with the intermediate bearing
make sure that the screws -1- are within the four centering tabs.
– Align the exhaust system, without tightening ⇒ Engine ⇒ Rep.
Gr. 26 .
– Install pendulum support at the gearbox ⇒ Chassis ⇒ Rep.
Gr. 40 .
Note

♦ Please observe the corresponding fixing screws and the tight‐
ening torque for the pendulum support ⇒ Chassis ⇒ Rep. Gr.
40 .

OCTAVIA II 2004 ➤
Note
♦ If droning noises occur while driving, the following must be

observed.
♦ Remove balancing nut and balancing washer -arrows-.
♦ Afterwards unscrew if necessary the propshaft with the flexible
disk from the flange of the Haldex coupling and screw on again
offset to a hole.
♦ If the droning noises can still be heard, the propshaft must be
screwed on once again offset to a hole.
Tightening torques
Component Nm
Intermediate bearing to body ⇒ page 233
Front to rear propshaft pipe ⇒ page 233
Flexible disk to rear final drive ⇒ page 233
Flexible disks to propshaft1 ⇒ page 233
Flexible disk to angle gearbox ⇒ page 233
Parts .
4.2 Removing and installing “one-piece”

propshaft
Note
♦ The “one-piece” propshaft is installed as of 28.05.07. The front

propshaft pipe cannot be separated from rear propshaft pipe.
♦ Work on the propshaft should be carried out on a two-pillar lift
platform.
♦ Before the removal, mark the position of all parts to each other.
Carry out the installation again in the same position, otherwise
the imbalance is too great, damages to the bearing and hum‐
ming noises could occur.
♦ Flexible disks to propshaft and corresponding fixing screws
are not supplied as spare parts. Thus in case of damage, the
entire propshaft must be replaced ⇒ Electronic Catalogue of
Original Parts .
♦ When removing, do not let the propshaft “hang”, always sup‐
port it.
♦ Always remove the propshaft horizontally from the centering
stud or push on.
4.2.1 Remove propshaft


OCTAVIA II 2004 ➤
– Removing the whole exhaust gas system ⇒ Engine ⇒ Rep.

Gr. 26 .
– Remove the heat protection plate below the propshaft
-arrows-.
– Place a suitable wooden wedge -A- onto the gearbox mount
and support the “rear” propshaft pipe.
– Secure the propshaft against falling down with a belt.
– Mark the position of the propshaft with flexible disk to the out‐
put flange of the angle gearbox.
– Unscrew propshaft from angle gearbox -arrows-.

Note
After unscrewing the fixing screws for the pendulum support at

the gearbox, the engine/gearbox unit swivels slightly towards the
front (direction front). Make sure that the gasket ring in the flange
of the propshaft is not damaged.
Vehicles with rear final drive “02D/0AV”

OCTAVIA II 2004 ➤

– Unscrew propshaft with flexible disk and oscillation damper

from rear final drive -arrows-.
Vehicles with rear final drive “0BR”


For further removal, secure the propshaft in the front area with a
2nd mechanic.

OCTAVIA II 2004 ➤
– Unscrew intermediate bearing of propshaft from the vehicle

-arrows-.
– Then guide the propshaft towards the front (direction front).
While doing so, if necessary slightly press the engine/gearbox
assembly forwards.
– Afterwards pull off the propshaft from the centering stud at the
rear final drive.
– Then pull off the propshaft from centering stud of the angular
gearbox.
Note
♦ Do not tilt propshaft when removing, detach horizontally from

centering stud of angular gearbox and from centering stud of
rear final drive. Gasket ring/centering bushing -arrow- must
not be damaged, otherwise the propshaft has to be replaced.
4.2.2 Install
following points:
When re-installing, fit all parts of the propshaft marked to each
other in the same position.
The gasket rings -arrow- in the flanges of the propshaft must not
be damaged when removing and installing. In case of damaged
gasket rings the propshaft must be replaced.
studs.
Fitting position:
Three protruding bushings at the angle gearbox flange or the
Haldex coupling flange and propshaft flange grip into the location
holes of the flexible disks.
– Install the propshaft on the flange of the Haldex coupling and

on the flange of the angle gearbox in such a way that the
markings -arrows- are on the same line.

OCTAVIA II 2004 ➤
Observe fitting location of the different collar screws.

small collar -arrow A- (M10 x Propshaft on front final drive
30) -A-
large collar -arrow B- (M10 x Propshaft on rear final drive
45) -B-
– Screw the pendulum support with new screws -arrow B- and

-arrow C- onto the gearbox ⇒ Engine ⇒ Rep. Gr. 10 .
Note

♦ Pay attention to the corresponding fixing screws and the tight‐
10 .
– Align intermediate bearing in its elongated holes in such a way

that the propshaft or the middle bearing is not under tension.
– Only screw down intermediate bearing after tightening the
propshaft -arrows-.
– Install the heat shield below the propshaft.
– Install exhaust system and align free of stress ⇒ Engine ⇒
Rep. Gr. 26 .
Note

observed.
♦ Unscrew the propshaft with the flexible disk from the flange of
the Haldex coupling and screw on again offset to a hole.

OCTAVIA II 2004 ➤
Tightening torques
Component Nm
Intermediate bearing to body ⇒ page 238
Propshaft to rear final drive ⇒ page 238
Propshaft to angle gearbox ⇒ page 238

OCTAVIA II 2004 ➤
5 Repairing propshaft
5.1 Repairing “two-piece” propshaft

♦ Drive bushing -MP3-402 (VW 244B)-
♦ Assembly device for drive shaft -MP3-422 (VW 391)-
♦ Strutting bushing -MP6-428 (VW 522)-
♦ Clamping device -MP6-429 (40-204A)-
♦ Separating device 12...75 mm , e.g. -Kukko 17/1-
♦ Hose binding claw
Note
♦ The two-piece propshaft is installed until 27.05.07. The front propshaft pipe pos. 5 can be separated from
rear propshaft pipe pos. 19.
♦ During the manufacture, the entire propshaft is balanced, in order to obtain the smoothest running possible.
The balancing of the entire propshaft or the individual propshaft pipes is not possible with workshop tools.
It is therefore essential to always replace the entire propshaft in case of damage to the front or the rear
propshaft pipe.
♦ Before the removal, mark the position of all parts to each other. Carry out the installation again in the same
position, otherwise the imbalance is too great, damages to the bearing and humming noises could occur.
5. Repairing propshaft 233

OCTAVIA II 2004 ➤
1 - Angle gearbox
tronic Catalogue of
Original Parts
3 - Flexible disk with heat
shield
❑ Fitting position: The
open side of the heat
shield faces towards the
gearbox
4 - 60 Nm
❑ Assignment
⇒ page 237
5 - Front propshaft pipe
❑ When installing and re‐
moving do not damage
the centering bushing
and gasket ring in the
middle of the flange
6 - 40 Nm
7 - Shim
8 - Open warm-type clamp
❑ tensioning ⇒ page 236
9 - Joint boot for CV joint
❑ drive out with drift pin
before pressing off the
CV joint
❑ check for damage
10 - Disc spring
❑ interlocked at inside di‐
ameter
❑ Fitting position: large diameter lies on the CV joint
11 - Gasket
❑ always replace (pull off protective foil and stick in joint) ⇒ Electronic Catalogue of Original Parts
12 - CV joint
❑ Grease filling: Push 25 g grease on each side (total 50 g) into the joint. Grease joint if necessary, when
replacing the joint boot.
13 - Circlip
❑ removing and installing with circlip pliers
14 - 45 Nm
15 - Washer
16 - Flange
17 - Intermediate bearing

OCTAVIA II 2004 ➤
❑ drive in ⇒ page 237
18 - 25 Nm
❑ attaches additionally the heat shield
19 - Rear propshaft pipe
❑ When installing and removing do not damage the centering bushing and gasket ring in the middle of the
flange
20 - 60 Nm
21 - Balancing nut
❑ not fitted to all propshafts
❑ if the collar screw Pos. 23 was detached, the balancing nut and the balancing washer Pos. 22 must not
be installed again
22 - Balancing washer
❑ not fitted to all propshafts
❑ if the collar screw Pos. 23 was detached, the balancing nut Pos. 21 and the balancing washer must not
be installed again
24 - Flexible disk with oscillation damper
Pressing off CV joint
Pressing on CV joint
– Carefully pressing on.
– Tighten tensioner -MP6-429- , propshaft must not be pressed
down in the tensioner -MP6-429- , otherwise this could result
in paint damage.
– If necessary eliminate paint damage as follows: Remove
grease residues with Nitro-diluent -L 001 600- . Apply 2-com‐
ponent acrylic paint -ALN 769 041- with hardener -ALZ 009
001- .

OCTAVIA II 2004 ➤
Tighten warm-type clamp

-A- Hose binding claw
In case of repair assign the warm-type clamp via ⇒ Electronic
catalogue of original parts .
Remove the flange
Install the flange
Remove the intermediate bearing

– The rubber guide of the intermediate bearing must be cut
through and the sheet covering must be removed.
-A- Separating device 12...75 mm e.g. -Kukko 17/1-
-B- extractor e.g. -Kukko 18/0-

OCTAVIA II 2004 ➤
Fitting position of the intermediate bearing

The longest land -A- points in direction of travel -arrow- to the left.
Drive in intermediate bearing

Drive in intermediate bearing up to the stop.
Fitting position of flexible disk with oscillation damper

The land on the outside diameter -arrows- points away from the
propshaft pipe.
Observe fitting location of the different collar screws

small collar -arrow A- Propshaft on front final drive
-A-
large collar -arrow B- Propshaft on rear final drive
-B-

OCTAVIA II 2004 ➤
5.2 Repairing “one-piece” propshaft
Note
♦ The “one-piece” propshaft is installed as of 28.05.07. The front propshaft pipe cannot be separated from
rear propshaft pipe.
♦ During the manufacture, the entire propshaft is balanced, in order to obtain the smoothest running possible.
The balancing of the entire propshaft is not possible with workshop tools. Thus in case of damage, the entire
propshaft must be replaced ⇒ Electronic Catalogue of Original Parts .
♦ Before the removal, mark the position of all parts to each other. Carry out the installation again in the same
position, otherwise the imbalance is too great, damages to the bearing and humming noises could occur.
♦ Flexible disks to propshaft and corresponding fixing screws are not supplied as spare parts. Thus in case
of damage, the entire propshaft must be replaced ⇒ Electronic Catalogue of Original Parts .
1 - Angle gearbox
2 - 60 Nm
❑ 3 pieces
❑ M10 x 30
❑ Assignment
⇒ page 239
3 - Propshaft
⇒ page 223
❑ When installing and re‐
moving do not damage
the centering bushing
and gasket ring in the
middle of the flange
❑ Fitting position: the in‐
termediate bearing Pos.
5 is located in the direc‐
tion of travel behind the
monoblock joint -arrow-
4 - 60 Nm
❑ 3 pieces
❑ M10 x 45
❑ Assignment
⇒ page 239
5 - Intermediate bearing
❑ align free of stress
❑ replace propshaft if
damaged
6 - 25 Nm

OCTAVIA II 2004 ➤
Observe fitting location of the different collar screws

small collar -arrow A- (M10 x Propshaft on front final drive
30) -A-
large collar -arrow B- (M10 x Propshaft on rear final drive
45) -B-

OCTAVIA II 2004 ➤
6 Removing and installing the rear final

drive
6.1 Summary of components - Removing and installing the rear final drive “02D/
0AV”
Note
-Arrow- points in direction of travel.
1 - Rear assembly carrier

2 - Nut
❑ 4 pieces
❑ Tightening torque ⇒
Chassis ⇒ Rep. Gr. 42
Parts
3 - Screw
❑ 4 pieces
❑ for cross member Pos.4
at assembly carrier Pos.
1
Parts
4 - Cross member
❑ no longer applicable for
steel assembly carrier
Parts
5 - Screw
❑ for drive shaft to rear fi‐
nal drive
6 - Drive shaft
⇒ Chassis ⇒ Rep. Gr.
42
❑ Replace the rubber-metal bearing ⇒ page 253
8 - Stop washer
❑ mount onto the rubber-metal bearing ⇒ page 241
9 - Screw
❑ 3 pieces
❑ Tightening torque ⇒ Chassis ⇒ Rep. Gr. 42

OCTAVIA II 2004 ➤
10 - Washer
❑ installed between final drive and assembly carrier
❑ Fitting position: Chamfer (smaller ∅) points towards the assembly carrier
11 - Stop washer
❑ mount onto the rubber-metal bearing ⇒ page 241
12 - Support
Fitting position of the rubber-metal bearings “rear top” and “front

bottom”. Fitting of the stop washer -B-
• Final drive in fitting position
bottom”:
♦ The rubber-metal bearings “rear top” point with the stud -A- to
the top
♦ The rubber-metal bearing “front bottom” points with the stud
-A- to the bottom
Fitting of the stop washer -B-
– Pull the studs -A- into the holes of the stop washer -arrows-.
The stop washer -B- is then connected captively with the rubber-
metal bearing.
6. Removing and installing the rear final drive 241

OCTAVIA II 2004 ➤
6.2 Summary of components - Removing and installing the rear final drive “0BR”
Note
The -arrow- shows the direction of travel.
1 - Rear assembly carrier

2 - Drive shaft
⇒ Chassis ⇒ Rep. Gr.
42
⇒ page 246
❑ Replace the rubber-
metal bearing
⇒ page 253
4 - Stop washer
❑ install on rubber-metal
bearing ⇒ page 241
5 - Screw
❑ 3 pieces
Parts
6 - Propshaft
⇒ page 223
7 - Washer
❑ installed between final
drive and assembly car‐
rier
❑ on certain vehicles 2
washers can also be
present
❑ install the same number
of washers as removed
8 - Stop washer
❑ install on rubber-metal bearing ⇒ page 241
6.3 Removing and installing the rear final

drive “02D/0AV”

OCTAVIA II 2004 ➤
6.3.1 Removing
– Remove the two rubber plugs -arrows- in the luggage com‐
partment floor.
– Unscrew both screws for the gearbox mount from the top
through the holes -arrows-.
– Remove the rear silencer ⇒ Engine ⇒ Rep. Gr. 26 .
– Check, if a marking (colour point) is present on the flexible disk

and at the flange on the Haldex coupling -arrows-. If not, mark
the position of the flexible disk and the flange on the Haldex
coupling to each other -arrows-.

– Support propshaft with a wooden wedge on the tunnel support.

If necessary remove rear flexible disk with oscillation damper
from the propshaft.
– Separate both drive shafts from rear final drive ⇒ Chassis ⇒
Rep. Gr. 42 .
Vehicles with aluminium assembly carrier:

OCTAVIA II 2004 ➤
Note
♦ In order to remove all the screws (4 pieces) of the cross mem‐

ber, the screw -arrow - for the holder of the retaining strap for
the heat shield of the fuel tank must be removed on the right
side of the vehicle. Carefully swivel down this heat shield when
removing the upper screw of the right cross member.
♦ The cross member is not fitted on vehicles with steel assembly
carrier.
– Remove cross member -1-.

– Removing anti-roll bar ⇒ Chassis ⇒ Rep. Gr. 42 .
– Disconnect plug connection -2- at top of the control unit.
– Unclip both gearbox ventilation hoses -arrows- at assembly

carrier.

OCTAVIA II 2004 ➤
low the rear final drive and secure the final drive.
– Unscrew the fixing screw -arrow- from the front bracket of the
final drive.
– Slightly lower final drive and carefully pull out the engine and
gearbox jack e.g. -V.A.G 1383A- from the rear assembly car‐
rier.
6.3.2 Install
following points:
When re-installing, assemble all the parts of the propshaft marked
to each other in the same position.
The gasket ring -arrow- in the flange of the propshaft must not be
damaged when removing and installing. In case of damaged gas‐
ket ring the propshaft must be replaced.
studs.
Fitting position:
Three protruding bushings at the Haldex coupling flange or the
propshaft flange grip into the location holes of the rear flexible
disks with oscillation damper.
– Install the propshaft on the flange of the Haldex coupling in

such a way that the markings -arrows- are on the same line.

OCTAVIA II 2004 ➤
Note
♦ When replacing the rear final drive, the axle oil ⇒ page 306
and the oil for the Haldex coupling ⇒ page 300 must be
checked and topped up if necessary.
observed.
♦ Remove balancing nut and balancing washer -arrows-.
♦ Afterwards unscrew if necessary the propshaft with the flexible
disk from the flange of the Haldex coupling and screw on again
offset to a hole.
Tightening torques
Component Nm
Retaining strap for the heat shield of 25
the fuel tank1
Flexible disk to propshaft ⇒ page 233
Rear final drive to assembly carrier1 ⇒ Chassis ⇒ Rep. Gr. 42
Parts .
6.4 Removing and installing the rear final

drive “0BR”
♦ Socket insert -T10061-
6.4.1 Removing
– Remove the luggage compartment-floor covering.
– Remove the two rubber plugs -arrows A- in the luggage com‐
partment floor.
– Release both screws -arrow B- for the rear final drive to the
assembly carrier from the top through the holes in the luggage
compartment floor. Thus, the socket insert -T10061- can be
used.
– Raise vehicle.

OCTAVIA II 2004 ➤

Note

– Remove the rear part of the exhaust system as from the

clamping sleeve ⇒ Engine ⇒ Rep. Gr. 26 .
– Remove the heat shield below the propshaft.
– Unscrew screws -arrow B- and -arrow C- and remove pendu‐

lum support from gearbox.
Note
Do not release screw -arrow A-.
– Slacken the intermediate bearing of the propshaft from the

body by approx. 4 turns -arrows-.


OCTAVIA II 2004 ➤

– Push the engine/gearbox unit to the front with a 2nd mechanic

in -direction of arrow- and insert a suitable wooden wedge
-A- (approx. 50 mm thick) between the assembly carrier -B-
and the gearbox -C-.
– While doing so, remove the propshaft from the flange at the
Haldex coupling (centering stud) on the rear final drive.
Note
Do not tilt propshaft when removing, pull off horizontally from

centering stud of rear final drive. Gasket ring/centering bushing
-arrow- must not be damaged, otherwise the propshaft has to be
replaced.
– Tie up the rear part of the propshaft -A- for the suspension
-B- of the exhaust gas system.

OCTAVIA II 2004 ➤
So that the rear left vehicle level sensor -G76- -1- is not damaged.
– Disconnect the plug, unscrew the sender and place down on
the bottom suspension arm -A-.
– Unscrew both drive shafts at rear final drive.
– Removing anti-roll bar ⇒ Chassis ⇒ Rep. Gr. 42 .
Note
In order to unscrew and screw in the upper fixing screw

-top arrow- for the anti-roll bar clamp, remove the relevant drive
shaft from the flange shaft of the final drive and press upwards.
– Do not slacken the screw -arrow- at the front bracket more than
5 turns.
Note
The final drive is now loose.
– Raise the rear final drive -A- -arrow 1- and slide it as far to the
right as possible -arrow 2-.
– Remove the left drive shaft -B- from the flange and carefully
guide downwards.

OCTAVIA II 2004 ➤
left as possible -arrow 2-.
– Remove the right drive shaft -B- from the flange and carefully
guide downwards.
– Move the final drive back into its installed position.
– Place a suitable wooden wedge -A- onto the universal holder.

– Support the final drive with the engine and gearbox jack -V.A.G
1383 A- and secure it with the belt on the universal holder
against falling down.
– Release screw -B- at the front bracket.
– Remove the washer -C- from the top of the bracket.
– Swivel the final drive on the vehicle (see fig.) and at the same
time slightly lower.
– Disconnect the plug connection -A- on the four-wheel drive

control unit -J492- .
– Remove the ventilation lines -arrows- from the final drive.
– For removing, lower the final drive further and pull it “towards
the front”, ensuring adequate “distance” from the other com‐
ponents.
6.4.2 Install
following points:
– Secure the final drive with the belt of the universal holder
against falling down.

OCTAVIA II 2004 ➤
– Bring the final drive into the indicated position.
– Raise the final drive and guide the rear bracket -arrows- above
the assembly carrier, during this procedure ensure that there
is adequate free access to the adjoining components.
– Mount the plug connection -A- on the four-wheel drive control

unit -J492- .
– Install the ventilation lines -arrows- onto the ventilation pipes
of the final drive.
– Move the final drive into its installed position using the engine
and gearbox jack -V.A.G 1383 A- .
– Place the washer -C- on the front bracket.

– Tighten screw -B- by hand.
Note
The rear part of the final drive must be free in order to install the
drive shafts.
– Remove the engine and gearbox jack -V.A.G 1383 A- from

underneath the vehicle.

OCTAVIA II 2004 ➤
left as possible -arrow 2-.
– Carefully guide the right drive shaft -B- upwards into the
flange.
right as possible -arrow 2-.
– Carefully guide the left drive shaft -B- upwards into the flange.
– Install the anti-roll bar ⇒ Chassis ⇒ Rep. Gr. 42 .
Note
In order to unscrew and screw in the upper fixing screw

-top arrow- for the anti-roll bar clamp, grip the relevant drive shaft
in the flange shaft of the final drive and press upwards.
– Fit two “new” screws -arrow B- through the holes in the lug‐
gage compartment floor and tighten. Tightening torque ⇒
Chassis ⇒ Rep. Gr. 42 .
– Fit the two rubber plugs -arrows A- in the luggage compart‐
ment floor.

OCTAVIA II 2004 ➤
– Tighten the final drive from “below” -arrow-. Tightening torque

– Install propshaft at final drive and tighten. Tightening torque
⇒ page 223 .
– Tighten the drive shafts. Tightening torque ⇒ Chassis ⇒ Rep.
Gr. 42 .
– Tighten the pendulum support with “new” screws

-arrows B and C- at the gearbox. Tightening torques ⇒ engine
⇒ Rep. Gr. 10 .
– Align intermediate bearing free of stress and tighten. Tighten‐

ing torque ⇒ page 233 .
– Install rear left vehicle level sensor -G76- ⇒ Chassis ⇒ Rep.
Gr. 42 .
Carry out the basic setting of the headlight; to do so use ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
– Install exhaust system ⇒ Engine ⇒ Rep. Gr. 26 .
If the final drive was replaced:
– Check the oil level in the Haldex coupling, top up with oil if
necessary ⇒ page 300 .
– Check the oil level in the rear final drive, top up with oil if nec‐
essary ⇒ page 306 .
6.5 Replace rubber-metal bearing at the

rear final drive
♦ Drift pin -MP3-426 (30 - 505)-
♦ Assembly device -MP5 402 (3301)-
♦ Interior extractor 12 … 14.5 mm , e.g. -Kukko 21/1-
♦ Countersupport , e.g. -Kukko 22/1-

OCTAVIA II 2004 ➤
Note
The illustration shows the rear final drive “02D/0AV”. Replacing the rubber-metal bearings on the rear final drive
“0BR” is indentical.
1 - Stop washer
❑ remove before remov‐
ing the rubber-metal
bearing Pos. 2
❑ install onto the rubber-
metal bearings Pos. 2
⇒ page 257
2 - Rubber-metal bearing “rear
top”
rubber-metal bearings
“rear top” and “front bot‐
tom” ⇒ page 256
⇒ page 257
3 - Rubber-metal bearing “rear
bottom”
4 - Stop washer
❑ remove before remov‐
ing the rubber-metal
bearing Pos. 5
❑ install onto the rubber-
metal bearing Pos. 5
⇒ page 257
5 - Rubber-metal bearing “front
bottom”
rubber-metal bearings
“rear top” and “front bot‐
tom” ⇒ page 256
6 - Rubber-metal bearing “front top”

OCTAVIA II 2004 ➤
Pull out rubber-metal bearing “rear top”

B - Interior extractor 12 … 14.5 mm , e.g. -Kukko 21/1-
– A piece must be broken off from the collar of the rubber-metal
bearing in order to be able to position the countersupport
-arrow-.
– Insert the interior extractor into the joint of the upper and lower
rubber-metal bearing and put it under tension.
Drive out rubber-metal bearing “rear bottom”
Note
If the rubber-metal bearing should be replaced individually, it can

also be pulled out with the countersupport , e.g. -Kukko 22/1 - and
the interior extractor 12...14.5 mm , e.g. -Kukko 21/1-
⇒ page 255 .
Insert rubber-metal bearing “rear top” -A- and “rear bottom” -B-
Pull out the rubber-metal bearing “front bottom”

– Both ventilation pipes must be closed so that in the following
work step no oil escapes from the final drive.
– Then place the final drive with the upper part towards the bot‐
tom onto the work bench and pull out the rubber-metal bearing:
B - Interior extractor 12 … 14.5 mm , e.g. -Kukko 21/1-
– A piece must be broken off from the collar of the rubber-metal
bearing in order to be able to position the countersupport
-arrow-.
– Insert the interior extractor into the joint of the upper and lower
rubber-metal bearing and put it under tension.

OCTAVIA II 2004 ➤
Drive out rubber-metal bearing “front top”
Note
If the rubber-metal bearing should be replaced individually, it can

also be pulled out with the countersupport , e.g. -Kukko 22/1 - and
the interior extractor 12...14.5 mm , e.g. -Kukko 21/1-
⇒ page 255 .
Insert rubber-metal bearing “front bottom” -A- and “front top” -B-
Difference between the rubber-metal bearings “rear top” and

“front bottom”
The rubber-metal bearings “rear top” and “front bottom” differ in
height.
Dimension “a” mm Rubber-metal bearing
22 “rear top”
17 “front bottom”

OCTAVIA II 2004 ➤
Fitting position of rubber-metal bearings “rear top” and “front bot‐

tom”, fitting of the stop washer -B-
• Final drive in fitting position
bottom”:
♦ The rubber-metal bearings “rear top” ⇒ Item 2 (page 254) point
with the stud -A- to the top
♦ The rubber-metal bearing “front bottom” ⇒ Item 5 (page 254)
points with the stud -A- to the bottom
Fitting of the stop washer -B-
– Pull the studs -A- into the holes of the stop washer -arrows-.
The stop washer -B- is then connected captively with the rubber-
metal bearing.

OCTAVIA II 2004 ➤
7 Replace gasket rings for flange shaft

rear final drive (rear final drive instal‐
led)
♦ Catch pan
7.1 Removing and installing gasket ring for

flange shaft
7.1.1 Removing
The removal of the gasket ring is identical on both left and right.
– Remove drive shaft ⇒ Chassis ⇒ Rep. Gr. 42 .
– Place a catch pan under the rear final drive.
Remove the left flange shaft
– Manually screw the plate -1- of the extractor -T10037- with two
screws M8 (30 mm long) onto the flange shaft.
• The shoulders -arrows- for larger flange diameters point to the
outside.
– Position the nut of the knurled screw -2- of the extractor -
T10037- onto the hexagon screw -3-.
– Pull out the flange shaft with extractor -T10037- .
Removing the right flange shaft
– Manually screw the plate of the extractor -T10037- with two
screws M8 (30 mm long) onto the flange shaft.
• The shoulders for larger flange diameters point to the outside.
– Fit the nut of the knurled screw -arrow- of the extractor -

T10037- in such a way that the start of the thread is aligned
with the housing.
– Pull out the flange shaft with extractor -T10037- .
Proceed as follows for both sides

OCTAVIA II 2004 ➤
– Pull out gasket ring for flange shaft with ejection lever -
MP3-418- .
7.1.2 Install
– Lightly oil new gasket ring at outside diameter and drive in with
pressure plate -T10049- up to the stop, do not twist the gasket
ring.
– Clamp the flange shaft in a vice with protective jaws.

– Push out the old circlip from the flange shaft groove with the
new circlip -A-.
– Drive in the flange shaft with a rubber hammer.
– Install drive shaft ⇒ Chassis ⇒ Rep. Gr. 42 .
– Checking the oil level in the rear final drive ⇒ page 306 .
7. Replace gasket rings for flange shaft rear final drive (rear final drive installed) 259
OCTAVIA II 2004 ➤
8 Replace gasket ring for flange on the

Haldex coupling on installed rear final
drive
♦ Tensioning strap -T10038-
♦ Counterholder -T30004 (3415)-
♦ Three armed extractor e.g. -Kukko 12/1-
♦ Catch pan
♦ Bolt M10 x 25
♦ Allan screw M8 x 15
8.1 Remove and install gasket ring for

flange on the Haldex coupling
8.1.1 Removing
– Raise vehicle.
Note



Note

OCTAVIA II 2004 ➤




8. Replace gasket ring for flange on the Haldex coupling on installed rear final drive 261
OCTAVIA II 2004 ➤


– Support propshaft with Engine and gearbox jack , e.g. -V.A.G

1383A - .
Vehicles - “two-piece” propshaft
– If necessary remove rear flexible disk with oscillation damper
from the propshaft -arrows-.
Vehicles - “one-piece” propshaft

OCTAVIA II 2004 ➤
– Lash the vehicle securely to the lift platform using tensioning

straps -T10038- .
WARNING
If the vehicle is not lashed, there is a risk of the vehicle toppling

off the lift platform.
– Unscrew hexagon nut at flange of Haldex coupling.

-A- Screw M10 x 25
-B- Allen screw M8 x 15 (is screwed in from the reverse side into
the counterholder -T30004- )
– Disconnect flange for Haldex coupling. If there is any resist‐

ance, use three armed extractor , e.g. -Kukko 12/1- .
– Pull out gasket ring with ejection lever -MP3-418- .
OCTAVIA II 2004 ➤
8.1.2 Install
– Before installing, slightly oil new gasket ring on the outside
diameter and between the sealing lips with high efficiency oil
for Haldex coupling .
– Drive in new gasket ring with pressure plate -T10019- up to
the stop. Do not tilt the gasket ring during this process.
– Drive in flange for Haldex coupling.
tighten.
-A- Screw M10 x 25
– Install propshaft to final drive ⇒ page 223 .

⇒ Rep. Gr. 10 .
– Align intermediate bearing free of stress and tighten to tight‐

ening torque ⇒ page 233 .
Rep. Gr. 26 .
– Check oil level in the Haldex coupling ⇒ page 300

OCTAVIA II 2004 ➤
Tightening torques
Component Nm
Flange of Haldex coupling at rear final 210
drive1)
Flexible disk at propshaft (“two-piece” ⇒ page 233
propshaft)
1) Always replace nut ⇒ Electronic Catalogue of Original Parts .
OCTAVIA II 2004 ➤
9 Electrical/electronic components and

fitting locations for the Haldex cou‐
pling
9.1 Electric/electronic components and their fitting locations (final drive “02D/
0AV”)
1 - Four-wheel drive control

unit -J492 -
❑ Fitting location
⇒ page 267
❑ forms a single unit with
the control valve for
opening degree of cou‐
pling -N373-
❑ the pressure sensor is
also located in the con‐
trol unit - removing and
installing ⇒ page 272
❑ important signals from
the engine control unit
and the ABS control unit
with EDL -J104- are
transmitted via the data‐
bus to the four-wheel
drive control unit
2 - Pump for Haldex coupling -
V181-
⇒ page 267
❑ the pump can be inspec‐
ted with ⇒ Vehicle diag‐
nosis, testing and infor‐
mation system VAS
5051 in the operating
mode “Targeted fault
finding”
⇒ page 277
3 - Diagnostic connection
❑ is located in the front left
footwell, next to the front
flap control lever
4 - Switch for hand-brake control -F9-
❑ Fitting location ⇒ page 267
❑ the switch can be inspected with ⇒ Vehicle diagnosis, testing and information system VAS 5051 in the
operating mode “Targeted fault finding”
❑ removing and installing ⇒ Chassis ⇒ Rep. Gr. 46
5 - Brake light switch -F-
❑ Fitting location up to 10.05 ⇒ page 267
❑ Fitting location as of 11.05 ⇒ page 268
❑ the switch can be inspected with ⇒ Vehicle diagnosis, testing and information system VAS 5051 in the
operating mode “Targeted fault finding”
❑ removing and installing ⇒ Chassis ⇒ Rep. Gr. 46

OCTAVIA II 2004 ➤
Four-wheel drive control unit -J492-

Fitting location: Control unit -A- is located on the rear final drive,
in front (left) area.
Pump for Haldex coupling -V181-

Fitting location: Pump for Haldex coupling -arrow- is located on
the rear final drive, in front (right) area.
Switch for hand-brake control -F9-

Fitting location:Switch -arrow- is located on the hand-brake lever.
Brake light switch -F-

Fitting location: Brake light switch -F- is located on the foot con‐
trols above the brake pedal.
9. Electrical/electronic components and fitting locations for the Haldex coupling 267
OCTAVIA II 2004 ➤
Brake light switch -F- and brake pedal switch -F47-

Fitting location: Brake light switch -F- and brake pedal switch -
F47- are located on the master brake cylinder.
9.2 Electrical/electronic components and their fitting locations (final drive

“0BR”)

unit -J492-
⇒ page 267
❑ forms a single unit with
the control valve for
pling -N373- Pos. 2
❑ important signals from
the engine control unit
and the ABS control unit
with EDL -J104- are
transmitted via the data‐
bus to the four-wheel
drive control unit
2 - valve for control of the
opening degree of the coupling
-N373-
V181-
⇒ page 269
❑ the pump can be inspec‐
ted with ⇒ Vehicle diag‐
nosis, testing and infor‐
mation system VAS
5051 in the operating
mode “Targeted fault
finding”
⇒ page 279
4 - Diagnostic connection
❑ is located in the front left
footwell, next to the front
flap control lever
5 - Accelerator pedal position
sender -G79-
❑ Fitting location ⇒ page 269

OCTAVIA II 2004 ➤
Pump for Haldex coupling -V181-

Fitting location: The pump for Haldex coupling -2- is located on
the rear final drive, in front (right) area.
Accelerator pedal position sender -G79-

Fitting location: The accelerator pedal position sender -G79-
-arrow- is located on the foot controls.
OCTAVIA II 2004 ➤
9.3 Summary of components - Four-wheel drive control unit -J492- (final drive
“02D/0AV”)

unit -J492 -
❑ is calibrated with the
valve for control of the
opening degree of the
coupling -N373- pos. 4
❑ always replace together
with the valve for control
of the opening degree of
the coupling -N373-
pos. 4
⇒ page 272
2 - 6 Nm
3 - Cover
❑ with vulcanized gasket
tronic Catalogue of
Original Parts
-N373-
four-wheel drive control
unit -J492-
with the four-wheel drive
control unit -J492- Pos.
1
5 - Sealing ring
❑ Diameter 12 mm
❑ for valve for control of
the opening degree of
the coupling -N373-
❑ moisten with high efficiency oil for Haldex coupling and insert
6 - Sealing ring
❑ Diameter 11 mm
❑ for valve for control of the opening degree of the coupling -N373-
7 - Sealing ring
❑ in the housing of the Haldex coupling
8 - Sealing ring
❑ for pressure sensor

OCTAVIA II 2004 ➤
9 - Pressure sensor
❑ can be re-used when replacing the control unit
10 - Disc spring
Fitting position of the disc spring

The marking -arrow- on the curved side of the disc spring -2-
points in the fitting position upwards and towards the pressure
sensor -1-.
9.4 Summary of components - Four-wheel drive control unit -J492- (final drive
“0BR”)

unit -J492-
valve for control of the
opening degree of the
coupling -N373- pos. 4
with the valve for control
of the opening degree of
the coupling -N373-
pos. 4
⇒ page 272
2 - 6 Nm
3 - Cover
❑ with vulcanized gasket
❑ remains glued on the
control unit or on the
housing of the Haldex
coupling during removal
tronic Catalogue of
Original Parts
-N373-
four-wheel drive control
unit -J492-
with the four-wheel drive
control unit -J492- Pos.
1
⇒ page 272
OCTAVIA II 2004 ➤
5 - Sealing ring
❑ pay attention to correct fit of the centering lips in the groove
6 - Sealing ring
❑ Inner diameter 12 mm
7 - Sealing ring
8 - Sealing ring
9.5 Removing and installing the four-wheel

drive control unit -J492- (final drive
“02D/0AV”)
♦ Catch pan
9.5.1 Removing
Note
When removing the control unit -1-, the cover -2- and the disc
spring -5- are removed together. The pressure sensor -4- and the
valve -3- are removed separately.
– Switch off ignition.

OCTAVIA II 2004 ➤
– Separate plug connections -1- and -2- at the top of the control
unit.
– Place catch pan under the final drive.
– Release screws -arrows-.

Ensure that no parts fall down when removing the control unit.
– Carefully remove the control unit -A-.
– Carefully grasp the valve for control of opening degree of cou‐

pling -N373- -A- at the metal housing -arrow- using pliers and
pull out.
– Pull out pressure sensor -B-.
– Take gasket ring for control valve of opening degree of cou‐

pling -N373- -arrow- out of the housing.
9.5.2 Install
following points:
OCTAVIA II 2004 ➤
– Moisten new gasket ring for control valve of opening degree

of coupling -N373- -arrow- with high efficiency oil for Haldex
coupling and insert into the housing.
– Replace gasket rings -1- and -2- ⇒ Electronic Catalogue of

Original Parts .
Pay attention to the different diameters:
♦ Inside diameter of gasket ring -1- is 11 mm
– Replace gasket ring -arrow A- at pressure sensor.
Note
The marking -arrow B- on the curved side of the disc spring -2-
points in the fitting position upwards and towards the pressure
sensor -1-.
– Fit disc spring -2- with the curved side onto the pressure sen‐
sor -1-.
– Fit new cover -5- onto the control unit -6-.

– Insert pressure sensor -4- with disc spring into the new cover
-5- and press onto the plug connection. The curved side of the
disc spring points towards the pressure sensor.
– Coat new gasket ring from pressure sensor -4- with high effi‐
ciency oil for Haldex coupling .
– Insert valve -1- into the new cover -5- and the control unit
-6-. Press valve -1- onto the plug connection.
– Coat new gasket rings -2- and -3- with high efficiency oil for
Haldex coupling .

OCTAVIA II 2004 ➤
– Carefully fit on control unit -A- and tighten screws -arrows- to

tightening torque.
Tightening torque
Component Nm
Four-wheel drive control unit -J492- ⇒ Item 1 (page 270)
9.6 Removing and installing the four-wheel

drive control unit -J492- (final drive
“0BR”)
♦ Catch pan
9.6.1 Removing
– Separate plug connections -1- and -2- at the top of the control
unit.
– Release screws -arrows-.

Ensure that no parts fall down when removing the control unit.
– Carefully remove the control unit -A-.
OCTAVIA II 2004 ➤
– If necessary remove the cover ⇒ Item 3 (page 271) from the

housing of the Haldex coupling, while doing so hold the valve
-arrow-.
– Cover the control valve for opening degree of coupling -N373-

-arrow- with a cloth. Carefully grip the valve body -arrow- with
pliers and pull out the valve.
9.6.2 Install
following points:
– Replace gasket rings -1...4- ⇒ Electronic Catalogue of Origi‐
nal Parts .
Note
The valve gasket rings have different inner diameters.

♦ Gasket ring at valve body -4-
– First moisten the gasket ring -1- with high efficiency oil for Hal‐
dex coupling and position onto the control valve for opening
degree of coupling -N373- .
Then mount the gasket rings -2…4-.
Note
Press the centering lips (4 pieces) of the gasket ring -4- into the
groove on the valve.

OCTAVIA II 2004 ➤
– Fit new cover -2- onto the control unit -1-.
Note
The cover only fits in one position.
– Insert the control valve for opening degree of coupling -N373-

into the control unit -1-.
Note
The valve only fits in one position.
– Carefully fit on control unit -A- and tighten screws -arrows- to

tightening torque.
Tightening torque
Component Nm
Four-wheel drive control unit -J492- ⇒ Item 2 (page 271)
9.7 Removing and installing the pump for

Haldex coupling (final drive “02D/0AV”)
♦ Catch pan
9.7.1 Removing
OCTAVIA II 2004 ➤
– Release oil check screw -B-.

– Unscrew oil drain plug -A- and completely drain high efficiency
oil for Haldex coupling .
– Screw in oil drain plug -A- using a new gasket ring and tighten
to 30 Nm.
– Slightly lower the final drive, to do so the fixing screw must be

released by approx. 7 turns at the front bracket of the final
drive.
– Disconnect plug -arrow- for the pump from the control unit.
– Pull out wiring loom together with the holder -A- from the hous‐
ing and expose.
– Compress catch pegs -B- and push as far as possible into the
housing hole.

OCTAVIA II 2004 ➤
– Screw out the fixing screws of the pump -1-.

– Pull the pump -arrow- together with the cable protection -2- out
of the housing for the Haldex coupling.
9.7.2 Install
following points:
– Replace O-ring -1- and -2- ⇒ Electronic Catalogue of Original
Parts .
– Coat O-rings -1- and -2- thinly with high efficiency oil for Haldex
couplings .
– Fill up with high efficiency oil for Haldex coupling and check
oil level in the Haldex coupling ⇒ page 300 .
Tightening torques
Component Nm
Pump to Haldex coupling 6
Oil check screw2) 15
Oil drain plug2) 30
Rear final drive to assembly carrier 1 ⇒ Chassis ⇒ Rep. Gr. 42
Parts .
2)Using a new gasket ring ⇒ Electronic Catalogue of Original
Parts .
9.8 Removing and installing the pump for

Haldex coupling (final drive “0BR”)
♦ Catch pan
9.8.1 Removing
OCTAVIA II 2004 ➤

– Screw in new oil drain plug -A- and tighten to the prescribed
tightening torque.
– Slightly lower the final drive, to do so the fixing screw -arrow-

must be released by approx. 5 turns at the front bracket of the
final drive.
– Disconnect plug -arrow- for the pump from the control unit.
– Unclip the wiring loom -A- from the holders -arrows- and ex‐
pose.

OCTAVIA II 2004 ➤
– Screw out the fixing screws -1- of the pump for Haldex coupling
-V181- -2-.
– Pull the pump for Haldex coupling -V181- out of the housing
for the Haldex coupling in -direction of arrow-, to do so guide
through the wiring loom -3-.
9.8.2 Install
following points:
– Replace O-ring -1- and -2- ⇒ Electronic Catalogue of Original
Parts .
– Coat O-rings -1- and -2- thinly with high efficiency oil for Haldex
coupling .
Tightening torques
Component Nm
Pump to Haldex coupling 6
Oil drain plug2) 30
Rear final drive to assembly carrier1 ⇒ Chassis ⇒ Rep. Gr. 42
Parts .
2)Replace screw with sealing ring ⇒ Electronic Catalogue of
Original Parts .
OCTAVIA II 2004 ➤
10 Removing and installing Haldex cou‐

pling
10.1 Summary of components - Haldex coupling (final drive “02D/0AV”)
1 - 50 Nm
❑ 4 pieces
2 - Haldex coupling
❑ with control unit
⇒ page 283
3 - O-ring
⇒ page 283
tronic Catalogue of
Original Parts
❑ insert with high efficien‐
cy oil for Haldex cou‐
pling
❑ Oil specification ⇒ Elec‐
tronic Catalogue of
Original Parts
4 - Final drive
⇒ page 240

OCTAVIA II 2004 ➤
10.2 Summary of components - Haldex coupling (final drive “0BR”)
1 - 50 Nm
❑ 4 pieces
2 - Haldex coupling
❑ with control unit
⇒ page 283
3 - O-ring
⇒ page 283
tronic Catalogue of
Original Parts
❑ insert with high efficien‐
cy oil for Haldex cou‐
pling
❑ Oil specification ⇒ Elec‐
tronic Catalogue of
Original Parts
4 - Final drive
⇒ page 240
10.3 Removing and installing Haldex cou‐

pling (final drive installed)
♦ Guide bars -T10093-
♦ Catch pan
10.3.1 Removing
– Raise vehicle.
10. Removing and installing Haldex coupling 283

OCTAVIA II 2004 ➤

Note



Note



OCTAVIA II 2004 ➤





OCTAVIA II 2004 ➤
Note

centering stud of rear final drive. Gasket ring/centering bushing
-arrow- must not be damaged, otherwise the propshaft has to be
replaced.
– Support propshaft with Engine and gearbox jack , e.g. -V.A.G

1383A - .
– If necessary remove rear flexible disk with oscillation damper
from the propshaft -arrows-.
Vehicles - “one-piece” propshaft
– Disconnect plug connection -2-.


OCTAVIA II 2004 ➤

to tightening torque.
Note
Screw in new oil drain plug -A- on the rear final drive “0BR” and
tighten to tightening torque.
– Release fixing screws -arrows- and pull Haldex coupling out

of the rear final drive.
– Remove the previously installed O-ring -arrow- from the Hal‐

dex coupling.
10.3.2 Install
following points:
– Insert new O-ring and lightly oil with high efficiency oil for Hal‐
dex coupling ⇒ Item 3 (page 282) .
– Insert Haldex coupling -1- into the rear final drive. Screw in
guide bars -T10093- for precise guidance.
– Turn at flange/propshaft -2- and insert Haldex coupling up to
the stop.

OCTAVIA II 2004 ➤
– Unscrew guide bars -T10093- and tighten screws -arrows- to

specified tightening torque.
– Install propshaft at rear final drive ⇒ page 223 .

⇒ Rep. Gr. 10 .
– Align intermediate bearing free of stress and tighten to tight‐

ening torque ⇒ page 233 .
Rep. Gr. 26 .
Tightening torques
Component Nm
Oil drain plug1) 2) 30
Haldex coupling to rear final drive ⇒ Item 1 (page 282)
1)Using a new gasket ring ⇒ Electronic Catalogue of Original
Parts .
2) Replace oil drain plug on the rear final drive “0BR” ⇒ Electronic

OCTAVIA II 2004 ➤
11 Disassembling and assembling Hal‐

dex coupling
11.1 Summary of components - Disassembling and assembling “Haldex cou‐

pling of the 2nd generation” (final drive “02D/0AV”)
1 - Plate clutch
❑ Structure of the plate
clutch ⇒ page 290
⇒ page 292
2 - 6 Nm
V181-
⇒ page 277
4 - O-ring
❑ Diameter 32 mm
❑ for pump for Haldex
coupling -V181-
❑ moisten with high effi‐
ciency oil for Haldex
coupling and insert
tronic Catalogue of
Original Parts
5 - O-ring
❑ Diameter 30 mm
❑ for pump for Haldex
coupling -V181-
coupling and insert
tronic Catalogue of
Original Parts
6 - Screw cap, 35 Nm
7 - O-ring
❑ for cap
8 - Oil filter carrier
9 - O-ring
❑ for oil filter carrier
10 - O-ring
❑ for the oil filter
11. Disassembling and assembling Haldex coupling 289

OCTAVIA II 2004 ➤
11 - Oil filter
❑ for Haldex coupling
12 - Spring
13 - housing for Haldex coupling
❑ removing and installing complete Haldex coupling ⇒ page 282
❑ remove from plate clutch ⇒ page 292
14 - Nut, 210 Nm
❑ secure with locking agent -D 000 600-
15 - Flange for propshaft
16 - Gasket ring for flange/propshaft
Replace ⇒ page 260
17 - Circlip
18 - Ball bearing
19 - Four-wheel drive control unit -J492-
❑ with control valve of opening degree of coupling -N373-
❑ with oil level and oil temperature sender - G437-
20 - 6 Nm
21 - O-ring
Structure of the plate clutch

1- Plate clutch
Plates cannot be removed.
2- Outer rollers
3 pieces
3- Castors
3 pieces
Fitting position: Roller points to the outside.
4- Castors
3 pieces
Fitting position: Roller points to the inside.
5- Axial needle bearing
The thick washer points to the plate clutch -1-.

OCTAVIA II 2004 ➤
11.2 Summary of components - Disassembling and assembling “Haldex cou‐

pling of the 4th generation” (final drive “0BR”)
1 - O-ring
coupling and insert
tronic Catalogue of
Original Parts
2 - housing for Haldex coupling
❑ Removing and installing
Haldex coupling com‐
pletely ⇒ page 283
unit -J492-
❑ with control valve of
pling -N373-
⇒ page 275
4 - 6 Nm
5 - Gasket ring for flange of
propshaft
⇒ page 260
6 - Flange for propshaft
⇒ page 260
7 - Nut, 210 Nm
Parts
❑ secure with locking
agent -D 000 600-
8 - 50 Nm
❑ 4 pieces
❑ for housing of Haldex coupling Pos. 2 to rear final drive
9 - Cover
❑ for oil filter housing
❑ Oil filter change not necessary
10 - Cover
❑ for pressure tank
WARNING
The cover must never be
opened, risk of injuries!
11 - O-ring
❑ 2 pieces
❑ Diameter 34 mm
❑ for pump for Haldex coupling -V181-

OCTAVIA II 2004 ➤
12 - Pump for Haldex coupling -V181-
13 - 6 Nm
11.3 Replacing grooved ball bearing for Hal‐

dex coupling (final drive “02D/0AV”)
♦ Pipe section -MP3-409 (VW 418 A)-
♦ Assembly device -T10030-
♦ Tensioning strap -T10038-
♦ Counterholder -T30004 (3415)-
♦ Knock-in bushing -T30034 (41 - 501)-
♦ Pipe -T30055 (3296)-
♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Two-arm extractor , e.g. -Kukko 20/10-
♦ Catch pan
♦ Allan screw M8 x 15
♦ Bolt M10 x 25
11.3.1 Removing
– Raise vehicle.
Note



OCTAVIA II 2004 ➤

Note




OCTAVIA II 2004 ➤

Note

centering stud of final drive towards the rear. The gasket ring in
the centering bush -arrow- must not be damaged, otherwise the
propshaft must be replaced.
– Support propshaft.
– If necessary remove flexible disk from the propshaft -arrows-.
– Lash the vehicle securely to the lift platform using tensioning

straps -T10038- .
WARNING
If the vehicle is not lashed, there is a risk of the vehicle toppling

off the lift platform.

OCTAVIA II 2004 ➤
– Unscrew hexagon nut at flange of Haldex coupling.

-A- Screw M10 x 25
– Disconnect flange for Haldex coupling. If there is any resist‐

ance, use three armed extractor , e.g. -Kukko 12/1- .
– Pull out gasket ring with ejection lever -MP3-418- .
– Remove Haldex coupling ⇒ page 283 .

– Lay Haldex coupling onto a clean work bench.
– Remove housing for Haldex coupling.
-A- Two-arm extractor , e.g. -Kukko 20/10-

OCTAVIA II 2004 ➤
– Install circlip -1- for grooved ball bearing -2-.
– Press out grooved ball bearing.
11.3.2 Install
– Press in new grooved ball bearing up to the stop.
– Insert circlip -1-.

– Warm up grooved ball bearing -2- e.g. with a hot-air blower to
approx. 80°C.

OCTAVIA II 2004 ➤
– Centre the axial needle bearing -5…7- in the middle onto the
plate clutch -1-.
– Place the housing for the Haldex coupling onto the plate clutch
-1- by hand.
Note
The axial needle bearings -5…7- must not change their centered
position when placing on the housing.
– Before installing, slightly oil new gasket ring on the outside

diameter and between the sealing lips with high efficiency oil
for Haldex coupling .
– Drive in new gasket ring with pressure plate -T10019- up to
the stop. Do not tilt the gasket ring during this process.
– Press on flange/propshaft.

OCTAVIA II 2004 ➤
tighten. Tightening torque (final drive “02D/0AV”
⇒ Item 14 (page 290) ).
A - Hexagon screws M10 x 20
B - Allen screw M8 x 15 (is screwed in from the reverse side into
the counterholder -T30004 (3415)- )
– Install Haldex coupling ⇒ page 283 .
– Install propshaft at rear final drive ⇒ page 223 .
Rep. Gr. 26 .
Tightening torques
Component Nm
Haldex coupling to rear final drive ⇒ page 283
11.4 Removing and installing the oil filter for

Haldex coupling (final drive “02D/0AV”)
♦ Catch pan
Note
On vehicles with the rear final drive “OBR”, the oil filter for the
Haldex coupling is not replaced.
Removing
– Unscrew cap -arrow-.
– Pull out oil filter unit.

OCTAVIA II 2004 ➤
Install
following points:
– Install O-ring -2- onto the oil filter carrier -1-.
– Insert connecting spring -4- into the oil filter -3-.
– Screw in screw cap -arrow- with a new O-ring and tighten to

tightening torque ⇒ Item 6 (page 289) .

OCTAVIA II 2004 ➤
12 Check oil level in the Haldex coupling

or change oil or top up with oil
Note

4th generation”.
mixed.
Assignment of oil filler plugs and oil drain plugs

A - Filler screw for high efficiency oil for Haldex coupling
B - Oil drain plug for high efficiency oil for Haldex coupling
1 - Filler screw for gearbox oil
2 - Oil drain plug for gearbox oil
12.1 Check oil level in the Haldex coupling

♦ Catch pan
– Measure oil temperature ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
The oil temperature must be between 20 and 40 °C.
The oil temperature can be increased by warming up the engine.

OCTAVIA II 2004 ➤
Vehicles with aluminium assembly carrier
Note
♦ Always place cloth on cross member -arrows-.

♦ If the oil gets onto the cross member or into the recesses at
the cross member, it must be removed immediately.
♦ There is no cross member on vehicles with steel assembly
carrier.
– Release screw for oil inspection -arrow-. Shown on a removed

final drive for purposes of clear presentation.
Oil is at the correct level if the Haldex coupling is filled up to the
lower edge of the oil filler hole or at least 3 mm below the lower
edge of the oil filler hole.
– Screw in screw -arrow- using a new sealing ring and tighten
to 15 Nm.
12.2 Changing oil in the Haldex coupling

♦ Filling device -VAS 6291- or -VAS 6291A-
♦ Catch pan
– Raise vehicle.
– For changing, use the filling device , e.g. -VAS 6291- or -VAS
6291A- .
Note
♦ Always place a cloth on the cross member -arrows-.

carrier.
12. Check oil level in the Haldex coupling or change oil or top up with oil 301
OCTAVIA II 2004 ➤
– Release screw for oil inspection -B-. (Shown on a removed

final drive for purposes of clear presentation.)
– Screw out oil drain plug -A-.
– Drain oil.
to 30 Nm.
– Screw in adapter -A- up to the stop into the inspection hole.

– Lock angular piece -B- with adapter.
– Pull hose above the drive shaft.
The hose must not sag. It must come out above the left rear wheel.
– Lower the vehicle.

– Screw oil reservoir -A- onto filling device , e.g. -VAS 6291- or
-VAS 6291A- .
– Open valve -arrow- and hold oil reservoir as shown.
The Haldex coupilng is now filled with oil.

OCTAVIA II 2004 ➤
Note
♦ If the Haldex coupling is correctly filled, oil flows out at the

adapter -A-.
procedure.
– Raise vehicle.
– If oil flows out, place oil reservoir downwards below the level
of the Haldex coupling (e.g. on a tool car).
The excessive oil now flows back into the oil reservoir.
– Check oil level in the Haldex coupling.

to 15 Nm.
12.3 Refilling oil in Haldex coupling

♦ Catch pan
– Raise vehicle.
– For topping up, use filling device , e.g. -VAS 6291- or -VAS
6291A- .
Note
♦ Always place a cloth on the cross member -arrows-.

carrier.
OCTAVIA II 2004 ➤
– Release screw for oil inspection -arrow-. Shown on a removed

final drive for purposes of clear presentation.
– Screw in adapter -A- up to the stop into the inspection hole.

– Lock angular piece -B- with adapter.
– Pull hose above the drive shaft.
The hose must not sag. It must come out above the left rear wheel.
– Lower the vehicle.

– Screw oil reservoir -A- onto filling device , e.g. -VAS 6291- or
-VAS 6291A- .
– Open valve -arrow- and hold oil reservoir as shown.
The Haldex coupilng is now filled with oil.

OCTAVIA II 2004 ➤
Note
♦ If the Haldex coupling is correctly filled, oil flows out at the

adapter -A-.
procedure.
– Raise vehicle.
– If oil flows out, place oil reservoir downwards below the level
of the Haldex coupling (e.g. on a tool car).
The excessive oil now flows back into the oil reservoir.
– Check oil level in the Haldex coupling.

to 15 Nm.
OCTAVIA II 2004 ➤
13 Checking the gear oil level in the rear

final drive
Note

Assignment of oil filler and oil drain plug

A - Filler screw for high efficiency oil for Haldex coupling
B - Oil drain plug for high efficiency oil for Haldex coupling
1 - Filler screw for gearbox oil
2 - Oil drain plug for gearbox oil
13.1 Checking the gear oil level in the “rear

final drive 02D/0AV”
♦ Catch pan
• Vehicle on level ground.
– Unscrew screw -arrow- for oil inspection.
Oil is at the correct level if the rear final drive is filled up to the
– Insert screw -arrow- and tighten to tightening torque.
– Unscrew screw -arrow- for oil inspection.
– Pour in axle oil up to lower edge of filler hole.
– Insert screw -arrow- and tighten to tightening torque.
Tightening torque
Component Nm
Oil check screw M 10 15
Oil check screw M 20 40

OCTAVIA II 2004 ➤
13.2 Checking the gear oil level in the “rear

final drive 0BR”
♦ Catch pan
• Vehicle on level ground.
– Unscrew screw -1- for oil inspection.
Note
Do not unscrew the screws -2- (oil drain plug for rear final drive),
-A- (oil filler plug for Haldex coupling) and -B- (oil drain plug for
Haldex coupling).
Oil is at the correct level if the rear final drive is filled up to the
– Screw in new screw -1- and tighten to 15 Nm
– Unscrew screw -1- for oil inspection.
– Pour in gear oil up to lower edge of filler hole.
– Screw in new screw -1- and tighten to 15 Nm
13. Checking the gear oil level in the rear final drive 307
OCTAVIA II 2004 ➤
14 Inspect operation of Haldex coupling

“Final drive 02D/0AV” - Functional test for opened Haldex cou‐
pling on vehicles fitted with manual gearbox ⇒ page 308 .
“Final drive 02D/0AV” - Functional test for closed Haldex coupling
on vehicles fitted with manual gearbox ⇒ page 309 .
“Final drive 0BR” - Functional test of Haldex coupling with manual
gearbox ⇒ page 309 .
Before repairing the Haldex coupling, try to determine the origin
of the damage as accurately as possible using the ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 in the func‐
tions “Targeted fault finding”, “Vehicle self-diagnosis” and “Meas‐
uring method”.
14.1 “Final drive 02D/0AV” - Functional test

for opened Haldex coupling on vehicles
fitted with manual gearbox
Test requirements:
♦ Oil level of the Haldex coupling is O.K.
♦ Check oil level in the Haldex coupling ⇒ page 300
♦ Correctly fitted engine control unit and ABS control unit (check
coding and control unit identification number)
Note
For safety reasons, the vehicle must be placed on the lifting plat‐
form in such a way that the wheels have no contact with the
ground. Proceed carefully when inspecting.

– Start engine.
– Engage 1st gear and drive off slowly.
Now all 4 wheels must turn.
– Apply handbrake.
The rear wheels must come to a standstill, while the front wheels
continue to turn.
• If the rear wheels do not turn:
The Haldex coupling is open, the function is O.K.
• If the rear wheels turn:
The Haldex coupling is closed. Possible cause of fault:
♦ Main pressure regulating valve can clamp.
♦ Mechanical fault of the Haldex coupling.
♦ Four-wheel drive control unit -J492- on rear final drive is de‐
fective.
♦ Handbrake warning switch -F9- is defective.

OCTAVIA II 2004 ➤
14.2 “Final drive 02D/0AV” - Functional test

for closed Haldex coupling on vehicles
fitted with manual gearbox
Test requirements:
♦ Oil level of the Haldex coupling is O.K.
♦ Check oil level in the Haldex coupling ⇒ page 300
♦ Correctly fitted engine control unit and ABS control unit (check
coding and control unit identification number)
Note
For safety reasons, the vehicle must be placed on the lifting plat‐
form in such a way that the wheels have no contact with the
ground. Proceed carefully when inspecting.

– Start engine.
– Engage 2nd gear.
– Pull on the handbrake and slowly depress the clutch.
The engine must now stall.
• If the engine has stalled:
The Haldex coupling is closed, the function is O.K.
• If the engine has not stalled:
The Haldex coupling is open. Possible cause of fault:
♦ Main pressure regulating valve can clamp.
♦ Mechanical fault of the Haldex coupling.
♦ Four-wheel drive control unit -J492- on rear final drive is de‐
fective.
14.3 “Final drive 0BR” - Functional test of

Haldex coupling with manual gearbox
♦ Vehicle diagnosis, measurement and information system -
VAS 5051B- or vehicle diagnosis, measurement and informa‐
tion system -VAS 5052-
Before repairing the Haldex coupling, try to determine the origin
of the damage as accurately as possible using the ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 in the func‐
tions “Targeted fault finding”, “Vehicle self-diagnosis” and “Meas‐
uring method”.
14. Inspect operation of Haldex coupling 309

OCTAVIA II 2004 ➤
Note
♦ The Haldex coupling is tested on the lift platform using the

vehicle diagnosis, measurement and information system -VAS
5051B- or with the vehicle diagnosis, measurement and infor‐
mation system -VAS 5052- .
♦ For safety reasons, the vehicle must be placed on the lifting
platform in such a way that the wheels have no contact with
the ground. Proceed carefully when inspecting.
Functional test
WARNING
♦ Only the vehicle diagnosis, measurement and information

system -VAS 5051 B- or the vehicle diagnosis, measure‐
ment and information system -VAS 5052- must be used to
read the measured value blocks.
– When the ignition is switched off, connect the vehicle diagno‐

sis, measurement and information system -VAS 5051B- or the
vehicle diagnosis, measurement and information system -VAS
5052- to the diagnostic connection.
Fitting location: Cover in driver's footwell.
– Select “chassis” on the display.
– Select “four-wheel drive with Haldex coupling (4th generation)”
on the display.
– Select “01 - self-diagnosable system” on the display.
– Select “functions” on the display.
– Select “final control diagnosis” on the display.
– Follow the instructions on the tester.
– Select “functional test for Haldex coupling” on the display.
– Follow the instructions on the tester.

Gearbox 02Q

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Service

Service Department. Technical Information

2.3 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

39 - Final drive, differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

3.1 Summary of components - Front-wheel-drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.1 Location on the gearbox

Gearbox 02Q -arrow 2-

1. Identification of the gearbox 1

Identification characters and production date of the gearbox

The gearbox identification characters also appear on the vehicle

1.2 Identification of rear final drive

♦ The “Haldex coupling” is located in the rear final drive.

2 Rep. Gr.00 - Technical data

Rear final drive 02D

The identification characters do not appear on all final drives. If

-Arrow C- Production date

Rear final drive 0AV

The identification characters do not appear on all final drives. If

-Arrow C- Production date

1. Identification of the gearbox 3

Rear final drive 0BR

The identification characters do not appear on all final drives. If

-Arrow C- Production date

1.3 Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 6 speed 02Q

4 Rep. Gr.00 - Technical data

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

1. Identification of the gearbox 5

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

6 Rep. Gr.00 - Technical data

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

1. Identification of the gearbox 7

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

8 Rep. Gr.00 - Technical data

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

1. Identification of the gearbox 9

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

10 Rep. Gr.00 - Technical data

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

1. Identification of the gearbox 11

Manual gearbox 6 speed 02Q

Manual gearbox 6 speed 02Q

Ratio: Final drive for 1st gear through 69 : 16 = 3,875

Rear final drive 02D 0AV

12 Rep. Gr.00 - Technical data

Rear final drive 02D 0AV

Rear final drive 0AV