SKODA Fabia II 2007, Fabia II 2009, Fabia II 2011, Rapid 2011, Rapid NH 2013 Workshop Manual

...

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Page 1

Service

Workshop Manual

Fabia II 2007 ➤ , Fabia II 2009 ➤ ,

F Rapid NH 2013 ➤ , Rapid NH 2014 ➤ , Roomster 2006 ➤

abia II 2011 ➤ , Rapid 2011 ➤ ,

Gearbox 02T

Edition 05.2014

Service Department. Technical Information

Page 2

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

ep ai r Gr ou p

00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential

Page 3

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

Gearbox 02T - Edition 05.2014

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Identification characters, aggregate assignment, ratios, filling capacities (Fabia II) . . . . . . 1

1.2 Identification characters, aggregate assignment, ratios, filling capacities (Roomster) . . . . 6

1.3 Identification characters, aggregate assignment, ratios, filling capacities (Rapid) . . . . . . . . 10

1.4 Identification characters, aggregate assignment, ratios, filling capacities (Rapid NH) . . . . 11

2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.1 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 19

1.2 Removing and installing, setting angular clutch pedal switch F36 , (Fabia II 2007 ►; Roomster

2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3 Removing and installing, setting cylindrical clutch pedal switch F36 , (Fabia II 2007 ►;

Roomster 2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006

►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.5 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.6 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 27

1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013

►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.8 Summary of components - Foot controls (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.9 Removing and installing the bracket with the master cylinder (Fabia II 2011 ►; Roomster 2011

►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.10 Removing and installing the bracket with the master cylinder (Rapid 2011 ►) . . . . . . . . . . 41

1.11 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster

2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.12 Removing and installing the bracket without the master cylinder (Rapid 2011 ►) . . . . . . . . 44

1.13 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;

Roomster 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.14 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) . . . . 48

1.15 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster

2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) . . . . . . . . . . . . 51

1.17 Summary of components - Hydraulic (Rapid 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1.18 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.19 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . 58

1.20 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH

2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.21 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.22 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.1 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 70

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.2 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 79

1.4 Removing and installing gearshift knob and shift lever collar (Fabia II, Roomster) . . . . . . 79

Contents i

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Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014

1.5 Remove and install gearshift knob and shift lever collar (Rapid) . . . . . . . . . . . . . . . . . . . . 80

1.6 Remove and install gearshift knob and shift lever collar (Rapid NH) . . . . . . . . . . . . . . . . . . 81

1.7 Summary of components - Shift lever and shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.8 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . . . . . . . 87

1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . 89

1.11 Removing and installing shift mechanism (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.12 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3 Inspect the gear oil level in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.1 Gearbox - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 115

4.4 Detaching and attaching clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4.5 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and

gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4.6 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

7 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1 Replacing the flange shaft gasket rings (gearbox assembled) . . . . . . . . . . . . . . . . . . . . . . 151

1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.1 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

ii Contents

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

00 – Technical data

1 Identification of the gearbox

(SRL000700; Edition 05.2014) Assignment Fabia II ⇒ page 1 . Assignment Roomster ⇒ page 6 . Assignment Rapid ⇒ page 10 . Assignment Rapid NH ⇒ page 11 . Location on the gearbox Identification characters and production date -arrow 1-. Identification of materials for the gearbox housing -arrow 2-.

Gearbox 02T - Edition 05.2014

Identification characters and production date of the gearbox

Example: JHN 17 11 6

Additional data depend on the manufacturing.

Note

I I I I

Identifica‐

tion charac‐

ters

Day Month Manufac‐

turing year

(2006)

The gearbox identification characters also appear on the vehicle data stickers.

Identification of materials for the gearbox housing There is lettering on aluminium gearboxes -arrow- -GD TL 023-,

or -AlSi9Cu3- or -AlSi6Cu4-. One can also use the gearbox identification characters to deter‐

mine whether it is an aluminium or a magnesium gearbox.

1.1 Identification characters, aggregate assignment, ratios, filling capacities (Fabia II)

Manual gearbox 5 speed 02T Identification characters JHN LVC JUS LVG

1. Identification of the gearbox 1

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Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Manufac‐

tured

Assign‐ ment:

Ratio: Final drive 67 : 16 = 4.188 Z2:Z

Filling capacity 2.0 litre Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 90 mm 100 mm 90 mm 100 mm

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 12.06 06.09 01.07 06.09

to 05.09 03.10 05.09 03.10

Engine 1.2 ltr./44 kW 1.2 ltr./51 kW

1. gear 49 : 13 = 3.769

2. gear 44 : 21 = 2.095

3. gear 43 : 31 = 1.387

4. gear 40 : 39 = 1.026

5. gear 39 : 48 = 0.813 40 : 47 = 0.851

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

On gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are changed (the springs are longer), at the same time the synchronizer ring for 3rd and 4th gear is changed as of this date ⇒ Electronic Catalogue of Original Parts .

Manual gearbox 5 speed 02T Identification characters LVC LNR

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 67 : 16 = 4.188 Z2:Z

Filling capacity 2.0 litre Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval Filled for life

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 09.10 03.10

Engine 1.2 ltr./55 kW 1.2 ltr./44 kW 1.2 ltr./51 kW

1. gear 49 : 13 = 3.769

2. gear 44 : 21 = 2.095

3. gear 43 : 31 = 1.387 41 : 32 = 1.281

4. gear 40 : 39 = 1.026 38 : 41 = 0.927

5. gear 39 : 48 = 0.813 37 : 50 = 0.74

2 Rep. gr.00 - Technical data

Page 7

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

Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Clutch control hydraulic

Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 100 mm 90 mm

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters MFX LMG

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 58 : 16 = 3.625 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 03.10 03.10

Engine 1.2 ltr./63 kW TFSI 1.2 ltr./77 kW TFSI

1. gear 49 : 13 = 3.769

2. gear 43 : 22 = 1.955

3. gear 41 : 32 = 1.281

4. gear 38 : 41 = 0.927

5. gear 37 : 50 = 0.74

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters JHQ LVE JHL LVA

1. Identification of the gearbox 3

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Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Manufac‐

tured

Assign‐ ment:

Ratio: Final drive 66 : 17 = 3.882 59 : 15 = 3.933 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 02.07 06.09 04.07 06.09

to 05.09

Engine 1.4 ltr./63 kW 1.6 ltr./77 kW

1. gear 49 : 13 = 3.769

2. gear 44 : 21 = 2.095

3. gear 43 : 31 = 1.387

4. gear 40 : 39 = 1.026

5. gear 39 : 48 = 0.813

05.09 05.10

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters MAB LNJ

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 68 : 15 = 4.533 59 : 15 = 3.933 Z2:Z

Filling capacity 2.0 litre Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval Filled for life

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 06.10 09.10

to 01.12 01.11

Engine 1.6 ltr./77 kW

1. gear 38 : 11 = 3.455 49 : 13 = 3.769

2. gear 43 : 22 = 1.955 44 : 21 = 2.095

3. gear 41 : 32 = 1.281

4. gear 37 : 42 = 0.881

5. gear 35 : 52 = 0.673

4 Rep. gr.00 - Technical data

Page 9

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

Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Clutch control hydraulic

Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 100 mm

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters NVS

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 64 : 14 = 4.571 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 02.12

Engine 1.6 ltr./77 kW

1. gear 38 : 11 = 3.455

2. gear 43 : 22 = 1.955

3. gear 41 : 32 = 1.281

4. gear 37 : 42 = 1.881

5. gear 35 : 52 = 0.673

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters JQM LVF

1. Identification of the gearbox 5

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Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Manufac‐

tured

Assign‐ ment:

Ratio: Final drive 64 : 19 = 3.368 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 02.07 06.09

to 05.09 09.10

Engine 1.4 ltr./51 kW TDI-PD

1. gear 49 : 13 = 3.769

2. gear 44 : 21 = 2.095

3. gear 43 : 31 = 1.387

4. gear 40 : 39 = 1.026

5. gear 38 : 49 = 0.776

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

1.2 Identification characters, aggregate assignment, ratios, filling capacities (Roomster)

Manual gearbox 5 speed 02T Identification characters HZK JHM JHM LVB

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 69 : 14 = 4.929 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 05.06 11.06 01.07 06.09

to 11.06 12.06 05.09 03.10

Engine 1.2 ltr./47 kW 1.2 ltr./51 kW

1st gear 49 : 13 = 3.769

2nd gear 44 : 21 = 2.095

3rd gear 43 : 31 = 1.387 4th gear 40 : 39 = 1.026 5th gear 38 : 49 = 0.776

6 Rep. gr.00 - Technical data

Page 11

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

Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Filling capacity 2.0 l

Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 90 mm

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters MKG MFX LMG

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 69 : 14 = 4.929 58 : 16 = 3.625 Z2:Z

Filling capacity 2.0 ltr. Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 90 mm 100 mm

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 04.10 04.10

Engine 1.2 ltr./51 kW 1.2 ltr./63 kW

1st gear 49 : 13 = 3.769 49 : 13 = 3.769

2nd gear 44 : 21 = 2.095 43 : 22 = 1.955

3rd gear 41 : 32 = 1.281 41 : 32 = 1.281 4th gear 37 : 42 = 0.881 38 : 41 = 0.927 5th gear 35 : 52 = 0.673 37 : 50 = 0.74

1.2 ltr./77 kW

TFSI

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

1. Identification of the gearbox 7

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Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Identification characters HZM JHN LVC

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 67 : 16 = 4.188 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 05.06 11.06 06.09

to 11.06 05.09

Engine 1.4 ltr./63 kW

1st gear 49 : 13 = 3.769

2nd gear 44 : 21 = 2.095

3rd gear 43 : 31 = 1.387 4th gear 40 : 39 = 1.026 5th gear 39 : 48 = 0.813

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters HXL JHL LVA MAB

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 59 : 15 = 3.933 68 : 15 = 4.533 Z2:Z

Filling capacity 2.0 l

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 05.06 11.06 06.09 06.10

to 11.06 05.09 05.10 01.12

Engine 1.6 ltr./77 kW

1st gear 49 : 13 = 3.769 38 : 11 = 3.455

2nd gear 44 : 21 = 2.095 43 : 22 = 1.955

3rd gear 43 : 31 = 1.387 41 : 32 = 1.281 4th gear 40 : 39 = 1.026 37 : 42 = 0.881 5th gear 39 : 48 = 0.813 35 : 52 = 0.673

8 Rep. gr.00 - Technical data

Page 13

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

Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T Specification ⇒ Electronic Catalogue of Original Parts

Gear oil change interval Filled for life Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅ 100 mm

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters NVS

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 68 : 15 = 4.533 Z2:Z

Reverse gear 35 : 24 x 24 : 11 =

Speedometer electronic

from 02.12

Engine 1.6 ltr./77 kW

1st gear 38 : 11 = 3.455

2nd gear 43 : 22 = 1.955

3rd gear 41 : 32 = 1.281 4th gear 37 : 42 = 0.881 5th gear 35 : 52 = 0.673

3.182

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

1. Identification of the gearbox 9

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Manual gearbox 5 speed 02T Identification characters HZL JHP LVD

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 65 : 18 = 3.611 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 08.06 11.06 06.09

to 11.06 05.09 03.10

Engine 1.4 ltr./51 kW TDI-PD

1st gear 49 : 13 = 3.769

2nd gear 44 : 21 = 2.095

3rd gear 43 : 31 = 1.387 4th gear 40 : 39 = 1.026 5th gear 38 : 49 = 0.776

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

1.3 Identification characters, aggregate assignment, ratios, filling capacities (Rapid)

Manual gearbox 5 speed 02T Identification characters MAB NVS

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 68 : 15 = 4.533 64 : 14 = 4.571 Z2:Z

from 09.11 04.12

to 03.12

Engine 1.6 ltr./77 kW

1. gear 38 : 11 = 3.455

2. gear 43 : 22 = 1.955

3. gear 41 : 32 = 1.281

4. gear 37 : 42 = 0.881

5. gear 35 : 52 = 0.673

10 Rep. gr.00 - Technical data

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Gearbox 02T - Edition 05.2014

Manual gearbox 5 speed 02T

Note

♦

Vehicles with ABS do not have the sender for speedometer -

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

G22- .

♦

1.4 Identification characters, aggregate assignment, ratios, filling capacities (Rapid NH)

Manual gearbox 5 speed 02T Identification characters MKG MFX LGQ

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 69 : 14 = 4.928 58 : 16 = 3.625 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 07.12 07.12 07.12

Engine 1.2 ltr./55 kW MPI 1.2 ltr./63 kW TSI

1st gear 49 : 13 = 3.769 49 : 13 = 3.769

2nd gear 44 : 21 = 2.095 43 : 22 = 1.954

3rd gear 41 : 32 = 1.281 41 : 32 = 1.281 4th gear 37 : 42 = 0.881 38 : 41 = 0.927 5th gear 35 : 52 = 0.673 37 : 50 = 0.74

1. Identification of the gearbox 11

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Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

Manual gearbox 5 speed 02T Identification characters MAB NVS

Manufac‐ tured

Assign‐ ment:

Ratio: Final drive 68 : 15 = 4.533 64 : 14 = 4.571 Z2:Z

Reverse gear 35 : 24 x 24 : 11 = 3.182 Speedometer electronic

from 07.12 07.12

Engine 1.6 ltr./77 kW MPI

1. gear 38 : 11 = 3.455

2. gear 43 : 22 = 1.955

3. gear 41 : 32 = 1.281

4. gear 37 : 42 = 0.881

5. gear 35 : 52 = 0.673

Note

♦

Vehicles with ABS do not have the sender for speedometer G22- .

♦

12 Rep. gr.00 - Technical data

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Gearbox 02T - Edition 05.2014

2 Overview of Transmission System

2.1 Designation of components and transmission ratio

Note

The arrow shows the direction of travel.

1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Drive shaft 5 - Output shaft 6 - Differential gear I - 1. gear II - 2. gear III - 3. gear IV - 4. gear V - 5. gear R - Reverse gear A - Final drive T - Speedometer drive

2. Overview of Transmission System 13

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3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Also note the basic rules on safety when performing repair procedures.

A number of generally valid notes for individual repair operations

- which are otherwise listed several times at numerous points in the workshop manual - are summarized here. They apply for this particular workshop manual.

Gearbox Gearboxes are constructed of aluminium and of magnesium

⇒ page 1 .

♦ Gearbox housing and clutch housing are made of the same

materials.

♦ Bolts and other attachments that come into direct contact with

the gearbox can have varying finishes depending on whether the gearbox is made of aluminium or magnesium.

♦ On gearboxes which are made of magnesium, the screws

must always be replaced for the following screw connections: Cover for gearbox housing at gearbox housing and clutch housing at gearbox housing.

♦ The use of substitute components causes contact corrosion.

This will result in damage to the gearbox.

♦ Bolts and other attachments should have a classification in the

⇒ Electronic Catalogue of Original Parts .

♦ When installing, ensure the dowel sleeves are correctly loca‐

ted between the engine and gearbox.

♦ When replacing the gearbox, pour in gear oil up to lower edge

of filler hole. ♦ Filling capacity and specification (Fabia II) ⇒ page 1 . ♦ Filling capacity and specification (Roomster) ⇒ page 6 . ♦ Filling capacity and specification (Rapid) ⇒ page 10 . ♦ Filling capacity and specification (Rapid NH) ⇒ page 11 . Gaskets and seals ♦ Clean contact surfaces thoroughly and apply sealant -

AMV 188 200 03- . ♦ Apply sealant evenly - not too thickly. ♦ Replace O-rings. ♦ Replace radial shaft seals.

14 Rep. gr.00 - Technical data

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Before installing Lightly lubricate the outside diameter of the gasket ring. Fill half

the space between the sealing lips -arrow- with grease - G 052 128 A1- .

After installing Check gear oil level, if necessary pour in oil up to lower edge of

filler hole ⇒ page 112 , specification: ♦ Fabia II ⇒ page 1 . ♦ Roomster ⇒ page 6 . ♦ Rapid ⇒ page 10 . ♦ Rapid NH ⇒ page 11 . Locking elements

♦ Replace circlips. ♦ Do not over-tension the circlips. ♦ Circlips must be positioned in the base of the groove. ♦ Replace roll pins. Fitting position: Slot longitudinal to power

flow -arrow-.

Gearbox 02T - Edition 05.2014

3. General repair instructions 15

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Nuts and bolts ♦ Slacken and tighten fixing screws and nuts of covers and

housings diagonally across in stages. ♦ Do not twist particularly sensitive parts - e.g. clutch pressure

plates - slacken and tighten diagonally across in stages. ♦ Specified torques given are for unlubricated nuts, bolts and

screws. ♦ Always replace the self-locking screws and nuts ⇒ Electronic

Catalogue of Original Parts . ♦ It is important to ensure at all bolted connections that the con‐

tact surfaces as well as the nuts and bolts are waxed only after

being installed, should this be necessary. ♦ Clean all threaded holes into which self-locking bolts were

screwed in, using a suitable thread tap to remove old locking

agent residues. Otherwise there is the risk that the self-locking

screw will shear when removing. Bearings ♦ New taper roller bearings are fitted as supplied and do not

require any additional lubrication. ♦ Fit needle bearings to the gearbox with some gearbox fluid. ♦ Replace all taper roller bearings belonging to one shaft at the

same time. As far as possible use bearings of the same make. ♦ Before installing, heat the inner rings of the bearing on a heat‐

ing plate or with the hot-air blower , e.g. -V.A.G 1416- , to

approx. 100°C, when installing press in axial and play-free up

to the stop. ♦ The temperature can be checked with a temperature measur‐

ing instrument. ♦ Do not exchange the outer and inner rings of bearings of the

same size. The bearings are matched in pairs. ♦ Position needle bearing with the lettered side (thicker end) to‐

wards the drift pin. Shims

♦ Gauge shims at several points with a micrometer. Different

tolerances allow to measure the required thickness for each

washer very precisely ⇒ electronic catalogue of original parts . ♦ Inspect washers for burrs and damage. ♦ Install only adjusting washers which are in perfect condition. Synchronizer rings

16 Rep. gr.00 - Technical data

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♦ 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 check

the inside of the ring for flattened parts (grooves worn).

♦ When installing the intermediate ring -B-, check outer contact

surface -arrow 2- and inner contact surface -arrow 3- for grooves, blue coloring (caused by overheating) and other

damages. ♦ Insert moist with some gearbox fluid. Pinions ♦ Clean and heat on a heating plate or with the hot-air blower ,

e.g. -V.A.G 1416- to approx. 100°C before pressing on. ♦ The temperature can be checked with a temperature measur‐

ing instrument. ♦ Check fitting position. Clutch control ♦ When removing gearbox, remove slave cylinder, do not de‐

tach the hoses. ♦ If the slave cylinder with connected hydraulic line is removed,

do not depress the clutch pedal. Otherwise the tappet is press‐

ed out of the slave cylinder. ♦ Do not tilt the clutch pressure plate; release and tighten cross‐

wise in small stages. ♦ If the clutch pedal does not return to its initial position after the

coupling procedure - clutch pedal in home position - the clutch

control must be bled ⇒ page 65 (further measures

⇒ page 57 ).

♦ In order to reduce unpleasant odours if the clutch is burnt,

thoroughly clean the clutch housing as well as the flywheel and

the engine on the side of the gearbox. Safety precautions for vehicles with start-stop system

Gearbox 02T - Edition 05.2014

WARNING

On vehicles with start-stop system, there is the risk of injury from automatic engine start.

♦ On vehicles with activated start-stop system (recogniza‐

ble by a message in the dash panel insert), the engine can start automatically if required.

♦ It is therefore necessary to ensure that the start-stop sys‐

tem is deactivated when carrying out work on the vehicle (ignition switched off; if required switch ignition on again).

3. General repair instructions 17

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30 – Clutch

1 Clutch control

Summary of components - foot controls (Fabia II 2007 ►; Room‐ ster 2006 ►) ⇒ page 19 .

Removing and installing, setting angular clutch pedal switch F36- , (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 20 .

Removing and installing, setting cylindrical clutch pedal switch F36- , (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 21 .

Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 22 .

Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 24 .

Removing and installing the clutch pedal (Fabia II 2007 ►; Room‐ ster 2006 ►) ⇒ page 27 .

Summary of components - foot controls (Fabia II 2011 ►; Room‐ ster 2011 ►; Rapid NH 2013 ►) ⇒ page 29 .

Summary of components - Foot controls (Rapid) ⇒ page 36 . Removing and installing the bracket with the master cylinder (Fa‐

bia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

⇒ page 38 .

Removing and installing the bracket with the master cylinder (Rapid 2011 ►) ⇒ page 41 .

Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

⇒ page 43 .

Removing and installing the bracket without the master cylinder (Rapid 2011 ►) ⇒ page 44 .

Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►; Roomster 2011 ►) ⇒ page 46 .

Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ⇒ page 48 .

Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

⇒ page 49 .

Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH ►) ⇒ page 51 .

Summary of components - Hydraulic (Rapid 2011 ►)

⇒ page 54 .

Check hydraulic clutch control ⇒ page 57 . Removing and installing the master cylinder (Fabia II 2007 ►;

Roomster 2006 ►) ⇒ page 58 . Removing and installing the master cylinder (Fabia II 2011 ►;

Roomster 2011 ►; Rapid NH 2013 ►) ⇒ page 61 . Remove and install slave cylinder ⇒ page 61 . Bleed the clutch control ⇒ page 65 .

18 Rep. gr.30 - Clutch

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1.1 Summary of components - foot controls

(Fabia II 2007 ►; Roomster 2006 ►)

Note

♦

Summary of components - Hydraulics ⇒ page 51 .

♦

If the battery earth strap is disconnected and connected, carry

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

♦

Grease all bearing points and contact surfaces with grease -

G 000 450 02- .

♦

Prior to working on the foot controls remove the storage area

on the driver's side ⇒ Body Work; Rep. gr. 70 .

1 - Support/Front wall

❑ for master cylinder and

bracket

2 - Gasket

❑ always replace ⇒ Elec‐

tronic Catalogue of

Original Parts 3 - Bearing bracket 4 - Screw 5 - Gas/brake foot controls 6 - 28 Nm

❑ always replace ⇒ Elec‐

tronic Catalogue of

Original Parts 7 - Clutch pedal switch -F36-

❑ Difference between

clutch pedal switch

⇒ page 20

❑ assign according to the

⇒ Electronic catalogue

of original parts .

❑ Removing and installing

⇒ page 20 angular

clutch pedal switch

❑ Removing and installing

⇒ page 21 cylindrical

clutch pedal switch 8 - Over-centre helper spring

❑ removing and installing

⇒ page 24

9 - Bushing 10 - Bearing pins 11 - Clutch pedal

❑ removing and installing ⇒ page 27

12 - Support

❑ removing and installing ⇒ page 27

Gearbox 02T - Edition 05.2014

1. Clutch control 19

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13 - 28 Nm

❑ always replace ⇒ Electronic Catalogue of Original Parts

14 - Master cylinder

❑ removing and installing ⇒ page 58

❑ test tightness ⇒ page 57 15 - Spring strap clamp 16 - Supply hose

❑ out of rubber

❑ as of 12.05 on certain vehicles out of plastic ⇒ page 54

❑ if the return hose is made out of plastic, do not use hose clamp - MP7-602-

❑ test tightness ⇒ page 57 17 - Bearings

❑ insert in bearing bracket

❑ always replace ⇒ Electronic Catalogue of Original Parts 18 - Screw

❑ Pedal stop on bracket -Pos. 319 - Pedal stop

❑ screw with screw -Pos. 18- onto bracket -Pos. 320 - 25 Nm

❑ always replace ⇒ Electronic Catalogue of Original Parts

Difference between clutch pedal switch -F36♦ -A- Switch with angular housing Removing and installing ⇒ page 20 ♦ -B- Switch with cylindrical housing Removing and installing ⇒ page 21

1.2 Removing and installing, setting angular

clutch pedal switch - F36- , (Fabia II 2007 ►; Roomster 2006 ►)

Note

The clutch pedal switch - F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket.

20 Rep. gr.30 - Clutch

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Removing – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Unplug connector from the clutch pedal switch - F36- . – Turn clutch pedal switch - F36- 90° to the left and remove it

from the support. Installing and setting – Remove tappet up to the stop – Press down the clutch pedal by hand as far as possible. – Insert clutch pedal switch into the support and turn switch 90°

to the right. – Insert connector for the clutch pedal switch - F36- . – Install the storage area on the driver's side ⇒ Body Work; Rep.

gr. 70 .

1.3 Removing and installing, setting cylin‐

drical clutch pedal switch - F36- , (Fabia II 2007 ►; Roomster 2006 ►)

Gearbox 02T - Edition 05.2014

Note

The clutch pedal switch - F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket.

– Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Unplug connector -1- from the clutch pedal switch - F36- . – Turn clutch pedal switch - F36- -2- in the bracket 45° to the left

and remove it from the support.

Note

The clutch pedal remains in the off position in this case (do not depress).

Installing and setting

– Before installing the clutch pedal switch - F36- pull out tappet

-3- fully.

• Clutch pedal -4- in the off position. – Guide the clutch pedal switch - F36- through the assembly

opening, press against the clutch pedal and attach by turning

it 45° to the right. – Insert connector for the clutch pedal switch - F36- . – Install the storage area on the driver's side ⇒ Body Work; Rep.

gr. 70 .

1. Clutch control 21

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1.4 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)

Removing – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Release screws -arrows-. Install Installation is carried out in the reverse order.

22 Rep. gr.30 - Clutch

Page 27

Tightening torque

Crash strut to steering column 9 Nm

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

Gearbox 02T - Edition 05.2014

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1.5 Removing and installing the over-centre

helper spring (Fabia II 2007 ►; Roomster 2006 ►)

Special tools and workshop equipment required ♦ Pliers - T10005♦ Polycarbamide grease - G 052 142 A2Removing – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Remove crash strut (if present) ⇒ page 22 . – Remove clutch pedal switch ⇒ page 19 -Pos. 7-, if provided. – Unlock the actuating rod/master cylinder from the clutch pedal. Unlock the actuating rod/master cylinder from the clutch pedal as

follows: – Insert pliers - T10005- in the clutch pedal recesses. – Press together support and separate the clutch pedal from the

master cylinder.

– Push the over-centre helper spring against the bulkhead

-in the direction of the arrow- and remove from the bracket

from the bottom. Install

– Insert bearing for over-centre helper spring -arrow 1- in the

bracket holder. The peg of the bearing is located in the recess of the master cyl‐

inder -arrow 2-. – Insert over-centre helper spring in the bearing.

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– Press over-centre helper spring against the bearing and posi‐

tion on the support of the clutch pedal -arrow-.

– Position the clutch pedal with the master cylinder

⇒ page 27 .

– Install clutch pedal switch ⇒ page 19 -Pos. 7-.

– Install crash strut ⇒ page 22 . – Install the storage area on the driver's side ⇒ Body Work; Rep.

gr. 70 .

Gearbox 02T - Edition 05.2014

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Tightening torque

Crash strut to steering column ⇒ page 22

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1.6 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)

Special tools and workshop equipment required ♦ Pliers - T10005♦ Polycarbamide grease - G 052 142 A2Removing – Remove crash strut (if present) ⇒ page 22 . – Remove clutch pedal switch ⇒ page 19 -Pos. 7-, if provided. – Removing the over-centre helper spring ⇒ page 24 . – Put steering wheel in the lower position. – Unscrew nut -A-. – Slowly turn steering wheel in a suitable position. – Pull screw out of the bracket. – Remove clutch pedal. Install Installation is performed in the reverse order, pay attention to the

following points:

Gearbox 02T - Edition 05.2014

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

the master cylinder.

– To click in the support push the clutch pedal towards the front

wall -direction of the arrow- and make sure it catches correctly.

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Tightening torques

Crash strut to steering column ⇒ page 22 Clutch pedal to bracket

Always replace self-locking nut ⇒ Electronic Catalogue of Original Parts .

⇒ page 19

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1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

Note

♦

Summary of components - Hydraulics ⇒ page 51 .

♦

After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

♦

Grease all bearing points and contact surfaces with Polycarbamide Grease - G 052 142 A2- .

1 - Front wall

❑ with mount for bearing

bracket and master cyl‐ inder

2 - Bushing

❑ for the top location hole

in the bracket

❑ The bushings for the

bottom location hole in the bracket are located in the master cylinder

3 - Bearing bracket

❑ removing and installing

with master cylinder

⇒ page 38

❑ removing and installing

without master cylinder

⇒ page 43

4 - 25 Nm

❑ for bracket on front wall ❑ self-locking ❑ 3 pieces ❑ always replace ⇒ Elec‐

tronic Catalogue of Original Parts

5 - Clutch pedal switch - F36-

❑ removing and installing

⇒ page 31

6 - Crash strut

❑ is attached to the steer‐

ing column

❑ different versions ⇒

electronic catalogue of original parts

❑ removing and installing ⇒ page 32

7 - Screw

❑ for crash strut -Pos. 6- at steering column

❑ Tightening torque: ♦ Version with two screws - 9 Nm ♦ Version with one screw - 20 Nm

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Gearbox 02T - Edition 05.2014

8 - Stop

❑ for the clutch pedal

9 - Bearing bolt

❑ always replace ⇒ Electronic Catalogue of Original Parts

10 - Over-centre helper spring

❑ depending on the equipment version, a tension spring or an over-centre helper spring is installed ❑ Assign components via the ⇒ Electronic catalogue of original parts ❑ removing and installing ⇒ page 46

11 - Clutch pedal

❑ removing and installing with over-centre helper spring ⇒ page 46

❑ removing and installing with tension spring ⇒ page 49 12 - Bushing 13 - Tension spring with vibration damper

❑ depending on the equipment version, a tension spring or an over-centre helper spring is installed

❑ Assign components via the ⇒ Electronic catalogue of original parts

❑ is inserted on the bracket -Pos. 3- and on the clutch pedal

❑ removing and installing ⇒ page 31 14 - Cap 15 - Support

❑ only replace if the master cylinder has been removed

❑ removing and installing ⇒ page 51 16 - Master cylinder

❑ removing and installing ⇒ page 61 17 - Clamp

❑ to remove and install the tube-hose line pull out retaining clip up to the stop

❑ is pulled out from the side on certain master cylinders 18 - Gasket

❑ always replace ⇒ Electronic Catalogue of Original Parts

❑ stick onto the master cylinder 19 - Supply hose

❑ out of plastic ⇒ page 54 20 - Clutch position sender - G476-

❑ for vehicles with start-stop system

❑ Assign components via the ⇒ Electronic catalogue of original parts

❑ removing ⇒ page 39

❑ installing ⇒ page 40

❑ can be checked in the “targeted fault finding” ⇒ Vehicle diagnostic tester

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Removing and installing tension spring – Removing and installing with hook - 3438- . – Insert the vibration damper with the recess -arrows- as of the

2nd spring coil -arrows-.

1.7.1 Removing and installing clutch pedal switch - F36-

Note

The clutch pedal switch - F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket.

Gearbox 02T - Edition 05.2014

Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 80 .

Note

The clutch pedal switch is installed from the front wall.

– Unplug connector from the clutch pedal switch - F36- . – Turn the clutch pedal switch at the bracket 45° in

-direction of arrow- and remove it from the support.

Install

• The tappet -A- of the clutch pedal switch must not be pulled

out.

• Grease the tappet head -arrow-.

• Assign the grease via the ⇒ Electronic Catalogue of Original

Parts .

• When installing the clutch pedal switch the clutch pedal must

always remain in the off position. During the complete assem‐ bly, the clutch pedal must only be touched with the tappet head

-arrow- of the clutch pedal switch .

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The clutch pedal switch is installed from the front wall. – Insert the clutch pedal switch into the support of the bracket

and turn it 45° in -direction of arrow-. – Insert connector for the clutch pedal switch . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 80 .

1.7.2 Removing and installing crash strut

The crash strut for the clutch pedal, which is installed on the steering column, is offered in two versions.

Version with two fixing screws Removing – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Release screws -arrows-. Install Installation is carried out in the reverse order.

Page 37

Tightening torque

Crash strut to steering column (2 screws) 9 Nm

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

Gearbox 02T - Edition 05.2014

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Version with one fixing screw Removing – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Release screw -arrow-. – Unclip the crash strut from the steering column. Install Installation is carried out in the reverse order.

Page 39

Tightening torque

Crash strut to steering column (1 screw) 20 Nm

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

Gearbox 02T - Edition 05.2014

Page 40

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1.8 Summary of components - Foot controls (Rapid)

Note

♦

Summary of components - Hydraulics ⇒ page 54 .

♦

After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical

System; Rep. gr. 27 .

♦

Grease all bearing points and contact surfaces with Polycarbamide Grease - G 052 142 A2- .

1 - Front wall

❑ with mount for bearing

bracket and master cyl‐ inder

2 - Bushing

❑ for the top location hole

in the bracket

❑ The bushings for the

bottom location hole in the bracket are located in the master cylinder

3 - Bearing bracket

❑ removing and installing

with master cylinder

⇒ page 41

❑ removing and installing

without master cylinder

⇒ page 44

4 - 25 Nm

❑ for bracket on front wall ❑ self-locking ❑ 3 pieces ❑ always replace ⇒ Elec‐

tronic Catalogue of Original Parts

5 - Clutch pedal switch - F36-

❑ removing and installing

⇒ page 37

6 - Stop

❑ for the clutch pedal

7 - Bearing bolt

❑ always replace ⇒ Elec‐

tronic Catalogue of Original Parts

8 - Over-centre helper spring

❑ removing and installing ⇒ page 48

9 - Clutch pedal

❑ removing and installing with over-centre helper spring ⇒ page 48 10 - Bushing 11 - Cap 12 - Support

❑ only replace if the master cylinder has been removed

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Gearbox 02T - Edition 05.2014

❑ removing and installing ⇒ page 54

13 - Master cylinder

❑ removing and installing ⇒ page 61

14 - Clamp

❑ to remove and install the tube-hose line pull out retaining clip up to the stop ❑ is pulled out from the side on certain master cylinders

15 - Gasket

❑ always replace ⇒ Electronic Catalogue of Original Parts ❑ stick onto the master cylinder

16 - Supply hose

❑ out of plastic ⇒ page 37

Plastic return hose -1-

• The gaskets -2- must be located in the return hose.

1.8.1 Removing and installing clutch pedal switch - F36-

Note

The clutch pedal switch - F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket for clutch pedal.

Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 80 .

Note

The clutch pedal switch is installed from the front wall.

– Unplug connector from the clutch pedal switch - F36- .

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– Turn the clutch pedal switch at the bracket 45° in

-direction of arrow- and remove it from the support.

Install

• The tappet -A- of the clutch pedal switch must not be pulled out.

• Grease the tappet head -arrow-.

• Assign the grease via the ⇒ Electronic Catalogue of Original Parts .

• When installing the clutch pedal switch the clutch pedal must always remain in the off position. During the complete assem‐ bly, the clutch pedal must only be touched with the tappet head

-arrow- of the clutch pedal switch .

The clutch pedal switch is installed from the front wall. – Insert the clutch pedal switch into the support of the bracket

and turn it 45° in -direction of arrow-.

– Insert connector for the clutch pedal switch . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 80 .

1.9 Removing and installing the bracket with

the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

Special tools and workshop equipment required ♦ Closing tool - T10249-

1.9.1 Removing

Note

After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

– If necessary, remove engine cover ⇒ Engine; Rep. gr. 10 . – Remove battery ⇒ Electrical System; Rep. gr. 27 . – Remove air filter housing ⇒ Engine; Rep. gr. 23 , or ⇒ Engine;

Rep. gr. 24 .

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– If the master cylinder is not accessible, remove the engine

control unit from the front wall ⇒ Engine; Rep. gr. 23 or ⇒

Engine; Rep. gr. 24 . – Lay a cloth under the master cylinder. – Detach return hose -1- at master cylinder and close with a

suitable tool, e.g. closing tool - T10249/1- .

Note

♦

Do not use the hose clamp - MP7-602- , otherwise the return

hose -1- will be damaged.

♦

During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this is the case, these

points must be cleaned thoroughly.

– Pull out the locking clip -2- on the master cylinder up to the

stop.

Note

On certain master cylinders, the locking clip -2- can also be pulled out from the side.

Gearbox 02T - Edition 05.2014

– Pull the tube-hose line -3- out of the master cylinder and close.

Vehicles with start-stop system – Unclip clutch position sender - G476- at master cylinder

-arrow A- and -arrow B-.

– Remove the clutch position sender with fitted electrical plug

connectors from the master cylinder. Continued for all vehicles

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 . – If present, remove crash strut ⇒ page 32 . – Put steering wheel in the highest position.

– Remove clutch pedal switch - F36- -1- ⇒ page 31 . – Unscrew the top fixing nut -arrow- for the bracket. To do so,

position an long extension on the nut in the opening between

the dash panel -2- and the bottom steering column trim panel

-3-.

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– Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.

1.9.2 Install

Installation is performed in the reverse order, pay attention to the following points:

Note

Position self-locking nuts -1- and -2- for bracket -3- on front wall.

– Install the clutch pedal switch - F36- ⇒ page 31 . – If present, install the crash strut ⇒ page 32 . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

Vehicles with start-stop system – Insert the clutch position sender - G476- with fitted electrical

plug connectors up to the stop on the master cylinder.

• The clutch position sender must lock in place -arrow A-. – For checking, pull at clutch position sender -arrow B-. Continued for all vehicles – Press in tube-hose line -3- onto the connection of the master

cylinder, until the locking clip -2- is heard to click into position. – Fit return hose -1- on the master cylinder. – For checking, pull on the line. – Bleed the clutch control ⇒ page 65 . – If removed, install the engine control unit at the front wall ⇒

Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr. 24 . – Install battery ⇒ Electrical System; Rep. gr. 27 . – Install air filter housing ⇒ Engine; Rep. gr. 23 or ⇒ Engine;

Rep. gr. 24 .

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Tightening torques

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Gearbox 02T - Edition 05.2014

Bracket/clutch pedal to front wall Master cylinder to front wall

Replace self-locking nut.

1.10 Removing and installing the bracket with the master cylinder (Rapid 2011 ►)

Special tools and workshop equipment required ♦ Closing tool - T10249-

1.10.1 Removing

– Lay a cloth under the master cylinder. – Using an extraction bottle extract as much brake fluid as pos‐

sible from the brake fluid reservoir.

– Detach return hose -A- at master cylinder and close with a

suitable tool e.g. closing tool - T10249/1- .

Note

♦

Do not use the hose clamp - MP7-602- , otherwise the return hose -A- will be damaged.

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this is the case, these points must be cleaned thoroughly.

⇒ page 29 -Position 4- ⇒ page 29 -Position 4-

– Remove the locking clip -B- on the master cylinder up to the

stop.

– Release and cut the tube-hose line -C- out of the master cyl‐

inder.

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 .

– Put steering wheel in the highest position.

– Unplug connector from the clutch pedal switch - F36- . – Unscrew the top fixing nut -arrow- for the bracket. To do so,

position an long extension on the nut in the opening between the dash panel -2- and the bottom steering column trim panel

-3-.

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– Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.

1.10.2 Install

Installation is performed in the reverse order, pay attention to the following points:

Note

Position self-locking nuts -1- and -2- for bracket -3- on front wall and tighten.

– Connect the connector to the clutch pedal switch - F36- .

– Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

– Press in tube-hose line -C- onto the connection of the master

cylinder, until the locking clip -B- is heard to click into position. – Fit return hose -A- on the master cylinder. – For checking, pull on the line. – Bleed the clutch control ⇒ page 65 .

Tightening torques

Bracket/clutch pedal to front wall

⇒ page 36 -Position 4-

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Gearbox 02T - Edition 05.2014

Master cylinder to front wall

Replace self-locking nut.

1.11 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

Special tools and workshop equipment required ♦ Pliers - T10005Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 . – If present, remove crash strut ⇒ page 32 . – Put steering wheel in the highest position. – Remove clutch pedal switch - F36- -1- ⇒ page 31 . – Unscrew the top fixing nut -arrow- for the bracket. To do so,

position an long extension on the nut in the opening between

the dash panel -2- and the bottom steering column trim panel

-3-.

⇒ page 36 -Position 4-

Unlock the actuating rod/master cylinder from the clutch pedal as follows:

– Pull clutch pedal slightly into the passenger compartment. – Press together both sides of the support using the pliers -

T10005- -arrows-.

– Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.

• The master cylinder is locked into position with the bracket.

• When removing the bracket, the master cylinder in the engine

compartment must be held by a 2nd mechanic. Install Installation is performed in the reverse order, pay attention to the

following points:

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Note

Position self-locking nuts -1- and -2- for bracket -3- on front wall.

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

the master cylinder.

– To click in the support -A-, press the clutch pedal towards the

front wall in -direction of arrow-. While doing so, make sure it

catches correctly in the support. – Install the clutch pedal switch - F36- ⇒ page 31 . – If present, install the crash strut ⇒ page 32 . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

1.12 Removing and installing the bracket

without the master cylinder (Rapid 2011 ►)

Special tools and workshop equipment required ♦ Pliers - T10005Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 . – Put steering wheel in the highest position. – Unplug connector from the clutch pedal switch - F36- . – Unscrew the top fixing nut -arrow- for the bracket. To do so,

position an long extension on the nut in the opening between

the dash panel -2- and the bottom steering column trim panel

-3-.

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Unlock the actuating rod/master cylinder from the clutch pedal as follows:

– Pull clutch pedal slightly into the passenger compartment. – Press both sides of the support inwards using the pliers -

T10005- -arrows-

– Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.

• The master cylinder is locked into position with the bracket.

• When removing the bracket, the master cylinder in the engine compartment must be held by a 2nd mechanic.

Install Installation is performed in the reverse order, pay attention to the

following points:

Gearbox 02T - Edition 05.2014

Note

Position self-locking nuts -1- and -2- for bracket -3- on front wall and tighten.

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

the master cylinder.

– To click in the support -A-, press the clutch pedal towards the

front wall in -direction of arrow-. While doing so, make sure it catches correctly in the support.

– Connect the connector to the clutch pedal switch - F36- . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

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1.13 Removing and installing the clutch pedal with the over-centre helper spring (Fa‐ bia II 2011 ►; Roomster 2011 ►)

Note

♦

Install clutch pedal with new bearing bolt.

♦

If only the over-centre helper spring should be removed, the clutch pedal must not be separated from the master cylinder.

Special tools and workshop equipment required ♦ Pliers - T10005♦ Allan key, wrench size 8 mm, commercially available Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 . – If present, remove crash strut ⇒ page 32 . – Remove clutch pedal switch - F36- ⇒ page 31 . – Unlock the actuating rod/master cylinder from the clutch pedal

as follows: – Pull clutch pedal slightly into the passenger compartment. – Press together both sides of the support using the pliers -

T10005- -arrows-.

– Remove the bearing bolt for the clutch pedal. – Turn the bearing bolt for the clutch pedal to the left

-in direction of arrow-, for this purpose use the hexagon socket

wrench -1-, wrench size 8 mm. While doing so, the catches -A- are destroyed. Then the bolts -B- are positioned horizontally. – Subsequently move the clutch pedal so that the bearing bolt

can be pulled out. – Remove over-centre helper spring. – Remove clutch pedal from bracket. Install

• Install the clutch pedal with a new bearing bolt.

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– The support -2- must be located on the actuating rod -1- of the

master cylinder.

– Press the support -2- into the recess on the clutch pedal -3-

until it clicks audibly into place.

– Insert the over-centre helper spring laterally from the bottom

into the support -A- in the bracket next to the tappet of the master cylinder and next to the clutch pedal.

• The area of the support -arrow- for the bearing bolt of the clutch pedal must be vertical.

Gearbox 02T - Edition 05.2014

– Now position the over-centre helper spring on the centering

pin of the clutch pedal -arrow-.

– Press on the clutch pedal slightly and insert a new bearing bolt. – Position the bolts -A- horizontally. – Turn the bearing bolt to the right -in direction of arrow-, for this

purpose use the hexagon socket wrench -1-, wrench size 8 mm.

• The catches -B- must click audibly into place.

Then the bolts -A- are positioned vertically. – Install the clutch pedal switch - F36- ⇒ page 31 . – If present, install the crash strut ⇒ page 32 . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

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1.14 Removing and installing the clutch pedal with the over-centre helper spring (Rap‐ id)

Note

Install the clutch pedal with a new bearing bolt.

Special tools and workshop equipment required ♦ Pliers - T10005♦ Allan key, wrench size 8 mm, commercially available Removing – Remove mounting bracket without master cylinder

⇒ page 44 .

– Remove the bearing bolt for the clutch pedal. – Turn the bearing bolt for the clutch pedal to the left

-in direction of arrow-, for this purpose use the hexagon socket

wrench -1-, wrench size 8 mm. While doing so, the catches -A- are destroyed. Then the bolts -B- are positioned horizontally to the fitting position. – Subsequently move the clutch pedal so that the bearing bolt

can be pulled out. – Remove over-centre helper spring. – Remove clutch pedal from bracket. Install

• Install the clutch pedal with a new bearing bolt.

– Insert the over-centre helper spring laterally from the bottom

into the support -A- in the bracket next to the tappet of the

master cylinder and next to the clutch pedal.

• The area of the support -arrow- for the bearing bolt of the clutch

pedal must be vertical.

– Now position the over-centre helper spring on the centering

pin of the clutch pedal -arrow-.

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– The support -2- must be located on the actuating rod -1- of the

master cylinder.

– Press the support -2- into the recess on the clutch pedal -3-

until it clicks audibly into place.

– Press on the clutch pedal slightly and insert a new bearing bolt. – Position the bolts -A- horizontally. – Turn the bearing bolt to the right -in direction of arrow-, for this

purpose use the hexagon socket wrench -1-, wrench size 8 mm.

• The catches -B- must click audibly into place. Then the bolts -A- are positioned vertically. – Install bracket without master cylinder ⇒ page 44 .

Gearbox 02T - Edition 05.2014

1.15 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

Note

♦

Install the clutch pedal with a new bearing bolt.

♦

If only the tension spring is removed, pay attention

⇒ page 51 .

Special tools and workshop equipment required ♦ Hook - 3438♦ Pliers - T10005♦ Allan key, wrench size 8 mm, commercially available Removing – Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 . – If present, remove crash strut ⇒ page 32 . – Remove clutch pedal switch - F36- ⇒ page 31 .

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– Unhook the tension spring e.g with hook - 3438- .

Note

Only observe the right part of the fig. -arrows- when installing.

Unlock the actuating rod/master cylinder from the clutch pedal as follows:

– Pull clutch pedal slightly into the passenger compartment. – Press together both sides of the support using the pliers -

T10005- -arrows-.

– Remove the bearing bolt for the clutch pedal. – Turn the bearing bolt for the clutch pedal to the left

-in direction of arrow-, for this purpose use the hexagon socket

wrench -1-, wrench size 8 mm. While doing so, the catches -A- are destroyed. Then the bolts -B- are positioned horizontally. – Subsequently move the clutch pedal so that the bearing bolt

can be pulled out. – Remove clutch pedal from bracket. Install

• Install the clutch pedal with a new bearing bolt.

• The support -2- must be located on the actuating rod -1- of the

master cylinder. – Insert a new bearing bolt in the bracket and the clutch pedal.

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– Position the bolts -A- horizontally. – Turn the bearing bolt to the right -in direction of arrow-, for this

purpose use the hexagon socket wrench -1-, wrench size 8 mm.

• The catches -B- must click audibly into place. Then the bolts -A- are positioned vertically. – Lock the clutch pedal with the support on the actuating rod of

the master cylinder.

– Hook in the tension spring. – Insert the vibration damper with the recess -arrows- as of the

2nd spring coil -arrows-. – Install the clutch pedal switch - F36- ⇒ page 31 . – If present, install the crash strut ⇒ page 32 . – Install the footwell vent ⇒ Heating and Air Conditioning; Rep.

gr. 87 .

Gearbox 02T - Edition 05.2014

1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH)

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1 - Brake fluid reservoir

❑ test tightness

⇒ page 57

2 - Supply hose

❑ out of rubber ❑ as of 12.05 on certain

vehicles out of plastic

⇒ page 54

❑ if the return hose is

made out of plastic, do not use hose clamp MP7-602-

❑ test tightness

⇒ page 57

3 - Master cylinder

❑ removing and installing

(Fabia II 2007 ►; Room‐ ster 2006 ►)

⇒ page 58

❑ removing and installing

(Fabia II 2011 ►; Room‐ ster 2011 ►; Rapid NH 2013 ►) ⇒ page 61

❑ after installing, bleed the

clutch control

⇒ page 65

❑ test tightness

⇒ page 57

4 - Locking clip

❑ to remove the tube-hose

line -Pos. 9- pull out of the master cylinder

-Pos. 3- up to the stop

5 - Support

❑ only replace if the master cylinder -Pos. 3- has been removed ❑ removing ⇒ page 53 ❑ installing ⇒ page 53

6 - Clutch pedal

❑ removing and installing ⇒ page 27

7 - 28 Nm

❑ always replace ⇒ Electronic Catalogue of Original Parts

8 - O-ring

❑ always replace ❑ Difference between the O-rings ⇒ page 53 ❑ assign according to the ⇒ Electronic catalogue of original parts . ❑ moisten with brake fluid before installing ❑ test tightness ⇒ page 57

9 - Tube-hose line

❑ assign according to the ⇒ Electronic catalogue of original parts . ❑ test tightness ⇒ page 57

10 - Support

❑ at front left frame side rails ❑ for clipping in the tube-hose line -Pos. 9-

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Gearbox 02T - Edition 05.2014

11 - Support

❑ holds the tube-hose line -Pos. 9- on the gearbox

❑ not fitted to all vehicles 12 - 20 Nm 13 - Locking clip

❑ to remove the tube-hose line -Pos. 9- pull out of the slave cylinder -Pos. 16- up to the stop 14 - Dust cap 15 - Vent valve

❑ Bleeding the clutch control ⇒ page 65 16 - Slave cylinder

❑ removing and installing ⇒ page 61

❑ after installing, bleed the clutch control ⇒ page 65 17 - Gearbox

Lift off the support -A- in -the direction of the arrow-.

Push the actuator rod/master cylinder in the support -A- in

-direction of the arrow-.

Difference between the O-rings

Pos. Version of line connection

-1- Line connection with round slot -arrow 1-

-2- Line connection with shoulder -arrow 2-

-3- Line connection with shoulder -arrow 2- and with round slot -arrow 3-

• In case of a line connection with round slot -arrow 1- and

-arrow 3-, O-rings must be inserted into the slots.

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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-

1.17 Summary of components - Hydraulic (Rapid 2011 ►)

1 - Brake fluid reservoir 2 - Spring strap clamp 3 - Supply hose 4 - Master cylinder

❑ removing and installing

⇒ page 61

❑ after installing, bleed the

clutch control

⇒ page 65

5 - Support

❑ only replace if the mas‐

ter cylinder -Pos. 4- has

been removed ❑ removing ⇒ page 55 ❑ installing ⇒ page 56

6 - Clutch pedal 7 - Clamp

❑ to remove the tube-hose

line -Pos. 14- pull it out

of the master cylinder up

to the stop

8 - 25 Nm

❑ self-locking ❑ always replace ⇒ Elec‐

tronic Catalogue of

Original Parts

9 - Brake lines 10 - Support

❑ attached to the vehicle

body ❑ for tube-hose line

-Pos. 14-

11 - Support

❑ attached to the vehicle body ❑ for tube-hose line -Pos. 14-

12 - Support

❑ attached to the vehicle body ❑ for tube-hose line -Pos. 14-

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Gearbox 02T - Edition 05.2014

13 - Gasket ring/O-ring

❑ pull onto line connection ❑ insert with brake fluid ❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 56 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

14 - Tube-hose line

❑ Assignment ⇒ Electronic Catalogue of Original Parts

15 - Support

❑ fixed at front left frame side rail ❑ for tube-hose line -Pos. 14-

16 - Support

❑ for tube-hose line -Pos. 14- on the gearbox ❑ not fitted to all vehicles ❑ Assignment ⇒ Electronic Catalogue of Original Parts

17 - Screw, 20 Nm

❑ not fitted to all vehicles

❑ Assignment ⇒ Electronic Catalogue of Original Parts 18 - Dust cap 19 - Vent valve

❑ Bleeding the clutch control ⇒ page 65 20 - Screw, 20 Nm 21 - Slave cylinder

❑ removing and installing ⇒ page 61

❑ after installing, bleed the clutch control ⇒ page 65 22 - Clamp

❑ to remove the tube-hose line -Pos. 14- pull it out of the slave cylinder up to the stop 23 - Gearbox

Lift off the support -A- in -the direction of the arrow-.

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Gearbox 02T - Edition 05.2014

Push the actuator rod/master cylinder in the support -A- in

-direction of the arrow-.

Gasket rings/O-rings for tube-hose lines

Pos. Version of line connection

-1- Line connection with round slot -arrow 1-

-2- Line connection with shoulder -arrow 2-

-3- Line connection with shoulder -arrow 2- and with round slot -arrow 3-

• In case of a line connection with round slot -arrow 1- and

-arrow 3-, O-rings must be inserted into the slots.

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1.18 Check hydraulic clutch control

Note

♦

If the master cylinder and/or slave cylinder must be replaced due to the predetermined fault, first of all check the hydraulic clutch control.

♦

If the slave cylinder with the connected tube-hose line is re‐ moved from the gearbox, do no longer depress the clutch pedal. Otherwise, the piston can be pressed out of the slave cylinder and thus be destroyed.

♦

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 little or no brake fluid in this chamber, there is a leak in the system.

♦

Traces of brake fluid on or below the gearbox, as well as on the noise insulation under the gearbox is a result, amongst others, of an external leak.

♦

In case of leakage, the corresponding component must be re‐ placed ⇒ Electronic Catalogue of Original Parts .

♦

Check the correct routing of the tube-hose line between the master and slave cylinder. The line must not be kinked or trap‐ ped.

♦

The brake pedal return must not be obstructed by moved or additional covers (floor coverings).

Gearbox 02T - Edition 05.2014

Inspect the complete hydraulic system for leaks. – Carry out a visual inspection of the following components of

the hydraulic clutch control for leaks: ♦ Check brake fluid level in the brake fluid reservoir. ♦ Return hose between brake fluid reservoir and master cylin‐

der. ♦ Master cylinder. ♦ Tube-hose line between master cylinder and slave cylinder. ♦ Connection points (plug and screw connections) also in a non-

visible area. ♦ Slave cylinder.

– Remove the slave cylinder (do not open the line system) and

check if no brake fluid drips out of the bellows, to do so remove

the bellows from the rod -arrow-. – If necessary, bleed the clutch control ⇒ page 65 . – Then depress the clutch pedal carefully, at the same time hold

the pedal in five different positions for approx. 20s over the

entire distance the pedal has to travel and check that the pedal

does not fall through on its own while being held (in five posi‐

tions). While doing so, a second mechanic must check if fluid

is leaking from the other components of the hydraulic clutch

control ⇒ page 57 .

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1.19 Removing and installing the master cyl‐ inder (Fabia II 2007 ►; Roomster 2006 ►)

Special tools and workshop equipment required ♦ Pliers - T10005♦ Hose clamp - MP7-602 (3094)-

1.19.1 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 engine cover ⇒ engine; Rep. gr. 10 . – Remove air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep.

gr. 24 . – Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 . – Pinch off return hose -A- 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). – Release the return hose -A- to the brake fluid reservoir and

shut it off in a suitable manner. – Pull locking clip -B- out of the master cylinder. – Release and cut the tube-hose line -C- out of the master cyl‐

inder. – Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 . – Remove crash strut for clutch pedal (if present) ⇒ page 22 . – Remove clutch pedal switch, if provided, ⇒ page 19 ,-Pos. 7-.

Note

To remove the master cylinder completely remove the clutch con‐ trol. Before removing first separate the master cylinder from the clutch pedal.

– Unlock the actuating rod/master cylinder from the clutch pedal.

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Unlock the actuating rod/master cylinder from the clutch pedal as follows:

– Insert pliers - T10005- in the clutch pedal recesses. – Press together support and separate the clutch pedal from the

master cylinder.

– Removing the over-centre helper spring ⇒ page 24 .

– Unscrew the nuts -arrows 1- and remove the clutch controls

-arrow A- together with the master cylinder. – Unscrew pedal stop ⇒ page 19 ,-Pos. 19-. – Remove the master cylinder.

Gearbox 02T - Edition 05.2014

1.19.2 Install

Installation is performed in the reverse order, pay attention to the following points:

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

the master cylinder.

– To click in the support push the clutch pedal towards the front

wall in the -direction of the arrow-; while doing so make sure it catches correctly.

– After installing the master cylinder bleed the clutch control

⇒ page 65 .

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Tightening torques

Crash strut to steering column ⇒ page 22 Clutch pedal to bracket

Always replace self-locking nut ⇒ Electronic Catalogue of Original Parts .

⇒ page 19

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1.20 Removing and installing the master cyl‐

inder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

Special tools and workshop equipment required ♦ Pliers - T10005♦ Polycarbamide grease - G 052 142 A2Removing – Remove bracket with master cylinder: ♦ Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►

⇒ page 38 .

♦ Rapid 2011 ► ⇒ page 41 . – Unlock the clutch pedal from the master cylinder with the pliers

- T10005- . – Remove master cylinder from mounting bracket. Install – Insert the master cylinder in the bracket.

Gearbox 02T - Edition 05.2014

– The bracket -2- must be located on the actuating rod -1-. – Press the support -2- into the recess on the clutch pedal -3-

until it clicks audibly into place. – Install bracket with master cylinder: ♦ Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►

⇒ page 38 .

♦ Rapid 2011 ► ⇒ page 41 .

1.21 Removing and installing the slave cylin‐

der

Special tools and workshop equipment required ♦ Hose clamp - MP7-602 (3094)♦ Grease - G 000 100-

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Note

♦

If the slave cylinder must be replaced due to a predetermined fault, first of all check the hydraulic clutch control ⇒ page 57 .

♦

When performing the following work, make sure no brake fluid comes into contact with the gearbox. If this is the case, these points must be cleaned thoroughly.

1.21.1 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 . – If present, remove engine cover ⇒ Engine; Rep. gr. 10 . – Remove air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep.

gr. 24 . – Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 . – Remove circlip -arrow 1- for shift cable from gearbox shift lever

-A-.

Vehicles Fabia II and Roomster up to 05.07 and vehicles Rapid (metal relay lever)

– Remove circlip -arrow 2- for selector cable from relay lever

-B-. – Remove selector cable and shift cable from the studs. – Detach circlip -arrow 3- from the relay lever -B- and remove

relay lever.

Vehicles Fabia II and Roomster as of 06.07 and vehicle Rapid NH (plastic relay lever)

– Pull off shift cable from the stud. – Remove relay lever together with cable lock ⇒ page 87 . Continued for all vehicles – Remove the gearshift lever -A-, for this step unscrew nut

-arrow 4-.

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– Disconnect the Bowden cable support from gearbox

-arrows-. – Tie up shift cable and selector cable. – Place a non-fluffing cloth under the slave cylinder.

Note

Make sure no brake fluid comes into contact with the gearbox. If this is the case, this point must be cleaned thoroughly.

– Pinch off the tube-hose line to the master cylinder with the

hose clamp - MP7-602 (3094)- (if the tube-hose line to the master cylinder is made out of plastic, do not use the hose clamp - MP7-602- ).

– Pull retaining clip -A- for tube-hose line out of the slave cylinder

up to the stop. – Pull tube-hose line out of the support -C-. – Pull tube-hose line -B- out of the slave cylinder and close

opening in a suitable manner. – Unscrew slave cylinder -arrows- and take out.

Gearbox 02T - Edition 05.2014

Note

Do not depress the clutch pedal.

1.21.2 Install

Installation is performed in the reverse order, pay attention to the following points:

– Grease tappet head with grease - G 000 100- . – Install slave cylinder and tighten screws -arrows- to the given

tightening torque. – Insert tube-hose line -B- into the slave cylinder up to the stop. – Press in retaining clip -A- for attaching the tube-hose line up

to the stop. – Press tube-hose line up to the stop into the support -C- at the

gearbox. – After installing the slave cylinder bleed the clutch control

⇒ page 65 .

– Installing Bowden cable support, relay lever and gearshift lev‐

er: ♦ For vehicles Fabia II, Roomster and Rapid NH ⇒ page 89 . ♦ For vehicles Rapid ⇒ page 94 . – Setting the shift mechanism ⇒ page 96 . – Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 . – Install air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr.

24 . – Connect earth strap of battery ⇒ Electrical System; Rep. gr.

27 .

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Tightening torques

Slave cylinder to gearbox Fabia II, Roomster, Rapid NH ⇒ page 51

Rapid ⇒ page 54 Cable support to gearbox ⇒ page 84 Gearbox shift lever to gearbox ⇒ page 84

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1.22 Bleeding the clutch control

Special tools and workshop equipment required ♦ Brake filling and bleeding device , e. g. -VAS 5234-

Note

♦

If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox.

♦

A pre-filling of the system is not necessary!

Brake fluid specification ⇒ Chassis; Rep. gr. 00 . – If present, remove engine cover ⇒ Engine; Rep. gr. 10 . – 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 . – Connect the brake filling and bleeding device. – Fit the bleeder hose -A- on the vent valve of the slave cylinder

-arrow- and open the valve. – Activate system with a brake fluid pressure of 0.2 MPa. –

Allow approx. 100 cm3 of brake fluid to flow out until no more

air bubbles are visible. – Close vent valve. – Rapidly operate pedal from stop to stop 10 to 15 times. – Open vent valve. – Activate system with a brake fluid pressure of 0.2 MPa. –

Allow another approx. 50 cm3 of brake fluid to flow out. – Close vent valve. – After completing the bleeding procedure activate the clutch

pedal repeatedly. – If necessary, bleed the clutch control once again ⇒ page 65 . – Disconnect bleeding device.

Gearbox 02T - Edition 05.2014

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2 Repairing the clutch release mecha‐

nism

Special tools and workshop equipment required ♦ Grease - G 000 100-

1 - Clutch release bearing

❑ Do not wash the bear‐

ing, just wipe clean

❑ replace noisy bearings

⇒ Electronic Catalogue of Original Parts

❑ removing and installing

⇒ page 67

❑ remove and install to‐

gether with the clutch re‐ lease lever -Pos. 3- and guide bushing -Pos. 5-

⇒ page 67

❑ grease contact points

on the clutch release lever with grease - G 000 100-

2 - 5 Nm + 90° further

❑ always replace ⇒ Elec‐

tronic Catalogue of Original Parts

3 - Clutch release lever

❑ remove and install to‐

gether with the clutch re‐ lease lever -Pos. 1- and guide bushing -Pos. 5-

⇒ page 67

❑ Original grease must be

removed from the con‐ tact surface of the clutch release lever

❑ Grease contact surface

on the ball stud with grease - G 000 100-

4 - Retaining spring

❑ attach to clutch release lever

5 - Guide bushing for clutch release bearing

❑ removing and installing ⇒ page 67 ❑ remove and install together with the clutch release lever -Pos. 3- and clutch release bearing -Pos. 1-

⇒ page 67

❑ Grease guide bushing in the area of the release lever with grease - G 000 100-

6 - Gasket ring for drive shaft

❑ replace ⇒ page 126

7 - Ball stud, 20 Nm

❑ Original grease must be removed from the contact surface of the clutch release lever ❑ grease with grease - G 000 100-

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8 - Gearbox 9 - 20 Nm 10 - Support 11 - Slave cylinder

❑ removing and installing ⇒ page 61 ❑ Grease tappet head with grease - G 000 100-

Remove and install the clutch release lever together with the re‐ lease bearing and guide bushing

– Release screws -arrows-. – Separate the clutch release lever together with the release

bearing and guide sleeve from the drive shaft and ball stud. Installation is carried out in the reverse order.

Gearbox 02T - Edition 05.2014

Removing and installing the guide sleeve – Rotate the guide bushing -3- opposite the release bearing

-2- by approx. 90° in the -direction of the arrow- until the catch

pegs of the guide bushing are aligned with the slots -4- of the

release bearing. – In this position remove the guide sleeve from the release bear‐

ing. Installation is carried out in the reverse order.

Removing and installing the release bearing – Press the catch pegs -arrows- together and remove clutch re‐

lease bearing -A- from the clutch release lever. – To install press clutch release bearing -A- into the clutch re‐

lease lever until the catch pegs -arrows- lock into position.

2. Repairing the clutch release mechanism 67

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3 Repairing clutch

Fault finding power transmission - problems with the clutch and clutch control ⇒ page 70 .

Special tools and workshop equipment required ♦ Counterholder - MP1-223 (3067)♦ Centering mandrel - T10086♦ Centering mandrel - MP3-475A (3190A)♦ Grease - G 000 100(Gearbox removed)

Note

♦

Observe the fault finding of the power transmission before replacing the clutch disc and the pressure plate

- problems with the clutch and clutch control ⇒ page 70 .

♦

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 Catalogue of Original Parts .

♦

Clean the drive shaft serration and hub serration on used clutch discs. Remove corrosion and only apply a very thin layer of grease -G 000 100- on the drive shaft serration.

♦

Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft.

♦

Remove all excess grease.

♦

The pressure plates are protected against corrosion and are greased. Only clean the thrust surface as otherwise the life of the clutch may be considerably reduced.

♦

Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; insert if necessary.

♦

If the dowel sleeves are not installed, there are problems with the gearshift and the clutch or the gearbox is loud.

Page 73

1 - Flywheel

❑ make sure the centering

pins are correctly fitted

❑ The locating face for the

clutch lining must be free from grooves, oil and grease

❑ Removing and Installing

⇒ Engine; Rep. gr. 13

2 - Clutch disc

❑ Diameter ⇒ Electronic

Catalogue of Original Parts

❑ Fitting position: The

spring cage points to‐ wards the pressure plate

❑ centering for vehicles

with 1.2 ltr and 1.4 ltr en‐ gines ⇒ page 70

❑ centring for vehicles

with 1.4 ltr (TDI) and 1.6 ltr engines ⇒ page 70

❑ slightly grease the ser‐

ration

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Gearbox 02T - Edition 05.2014

Note

Clean the drive shaft serration and hub serration on used clutch discs, remove corrosion. Apply a very thin layer of grease - G 000 100- onto the serration. Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Remove all excess grease.

3 - Pressure plate

❑ removing and installing for vehicles with 1.2 ltr and 1.4 ltr engines ⇒ page 70 ❑ removing and installing for vehicles with 1.4 ltr (TDI) and 1.6 ltr engines ⇒ page 70 ❑ Check the extremities of the membrane spring ⇒ page 70

4 - Screw M6 - 13 Nm; screw M7 - 20 Nm

❑ loosen or tighten gradually and crosswise ❑ assign according to the ⇒ Electronic catalogue of original parts .

3. Repairing clutch 69

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Centering the clutch disc and removing and installing the pressure plate for vehicles with 1.2 ltr and 1.4 ltr engines

– Release and tighten screws gradually and crosswise. – When removing inverse the position of the pressure pad -

MP1-223 (3067)- .

Note

♦

The thrust surface of the pressure plate and the clutch disc lining must fully rest against the flywheel.

♦

Tighten the screws crosswise and uniformly so as not to dam‐ age the centering holes on the pressure plate and the center‐ ing pins of the flywheel.

Centering the clutch disc and removing and installing the pressure plate for vehicles with 1.4 ltr (TDI) and 1.6 ltr. engines

– Release and tighten screws gradually and crosswise. – When removing inverse the position of the pressure pad -

MP1-223 (3067)- .

Note

♦

The thrust surface of the pressure plate and the clutch disc lining must fully rest against the flywheel.

♦

Tighten the fixing screws crosswise and uniformly so as not to damage the centering holes on the pressure plate and the centering pins of the flywheel.

Check the extremities of the membrane spring

• Wear is allowed up to half the membrane spring thickness.

3.1 Fault finding power transmission - prob‐ lems with the clutch and clutch control

Note

Check hydraulic clutch control ⇒ page 57 .

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.

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Gearbox 02T - Edition 05.2014

Complaint Fault description Measure Clutch pedal does not return to ini‐

tial position.

♦ Air in line system. – Vent air from the line system;

top up with brake fluid.

♦ Line system, master or slave

cylinder leaking.

– Replace defective component,

vent air from the line system; top up with brake fluid.

♦ Release bearing is tilted on the

guide bushing, seizured.

– Replace guide bushing and re‐

lease bearing.

♦ Membrane spring of the pres‐

– Replace pressure plate.

sure plate broken.

Complaint Fault description Measure Actuating force on the clutch pedal

too high.

♦ Over-centre helper spring de‐

fective.

♦ The clutch release force has in‐

creased through the wear of the

– Replace over-centre helper

spring.

– Inform customer (higher release

force with increased wear).

clutch lining.

– Replace the clutch disc if the

distance base of the rivet is be‐ low 0.1 mm.

♦ Release bearing is tilted on the

– Replace defective components.

guide bushing, seizured.

♦ Pressure plate with wrong

spring identification.

– Assign pressure plate via the ⇒

Electronic catalogue of original parts .

♦ Mechanical fault at the pressure

– Replace defective components.

plate or the clutch disc.

♦ Clutch disc on the serration

sluggish/jams.

– Check the hub for damage

(burrs), if necessary replace clutch disc.

– Clean the hub and the drive

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

Complaint Fault description Measure Noises when operating the clutch. ♦ Release bearing defective,

guide of clutch release bearing

– Always replace noisy release

bearing. not in order, contact surface drained off.

– Replace damaged guide bush‐

ing.

♦ Contact surface of the pressure

– Replace pressure plate. plate defective (tips of mem‐ brane spring bent, broken). Re‐ lease bearing is off-center.

– Check release bearing and

guide bushing, replace if neces‐ sary.

– Check position of clutch release

lever.

– Check dowel sleeves.

3. Repairing clutch 71

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Complaint Fault description Measure

♦ Centre displacement of engine/

gearbox.

– Check dowel sleeves.

Complaint Fault description Measure Rattling, scratching occurs when

the forward or reverse gear is en‐ gaged, gearschift jams, is sluggish, shifting is not possible, clutch with‐ out operation.

♦ Clutch disc installed the wrong

way up.

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

♦ Air in the system, clutch does

not separate fully.

♦ Master cylinder or slave cylinder

is leaking, line is leaking.

♦ The travel of the clutch pedal is

not sufficent (carpet, foot mat under the foot controls), clutch is not fully depressed.

♦ The pressure plate is bent due

to incorrect installation, the clutch disc is deformed due im‐ proper handling.

♦ Tips of membrane spring broken

or bent (assembly fault, release bearing moves off-center).

– Correct installation.

Electronic catalogue of original parts .

– Bleed system; check system,

top up with brake fluid.

– Replace defective component,

top up with brake fluid, bleed system.

– Inform customer.

– Check components, if necessa‐

ry replace, make sure the cen‐ tering pins are correctly fitted.

– If scratching still occurs, check

the serration of the clutch disc on the drive shaft for ease of movement, if necessary repair the gearbox.

– Replace pressure plate.

– Check release bearing and

guide bushing, replace if neces‐ sary.

– Check dowel sleeves.

♦ Clutch disc too thick. – Assign clutch disc via the ⇒

Electronic catalogue of original parts .

♦ Deposit of corrosion adhering to

the flywheel (long immobiliza‐ tion time, high humidity).

– Slightly rub down friction surfa‐

ces of the clutch linings or re‐ place completely the severely corroded parts.

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Gearbox 02T - Edition 05.2014

Complaint Fault description Measure

♦ Clutch disc on the serration

sluggish/jams. Corrosion on the hub, damage during the assem‐

– Check the hub for damage, if

necessary replace the clutch

disc. bly. Hub profile knocked out on one side.

– Remove corrosion from the hub

and the shaft as well as residues

of lubricant. 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, guide

bushing and pressure plate, re‐

place if necessary.

♦ Lifting of pressure plate too low

(wrong pressure plate installed).

– Assign pressure plate via the ⇒

Electronic catalogue of original

parts .

♦ Displacement of engine/gear‐

box too large (dowel sleeves

– Insert dowel sleeves before

gearbox has been fitted. missing), support panel of clutch plate bent through this.

– Check clutch disc and pressure

plate for damage, if necessary

replace.

♦ The lining is spalled off because

of too high revs (shift back into

– Replace clutch disc. Inform cus‐

tomer. lower gears during high speeds).

♦ When starting, linings are spal‐

led off through slipping for too long a time.

Complaint Fault description Measure Load change jolts when throttle is

depressed and sudden reduction of the engine speed.

♦ Assembly bracket too soft. – Inform customer. Assign hanger

via the ⇒ Electronic catalogue

of original parts .

♦ Irregular engine running. – Check engine power, correct.

♦ Clutch disc with predamper is

– Inform customer.

built in against gear rattling.

♦ Centre displacement of engine/

gearbox.

– Test dowel sleeves, replace if

necessary.

Complaint Fault description Measure Clutch slips through, no or bad pre‐

drive.

♦ Wrong clutch disc fitted, wrong

pressure plate installed.

– Assign the clutch disc and pres‐

sure plate via the ⇒ Electronic

catalogue of original parts .

3. Repairing clutch 73

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Complaint Fault description Measure

♦ Clutch disc worn out, burnt,

pressure plate overheated, grooves, pressure plate de‐ formed through incorrect as‐ sembly, compressive force of the pressure plate too low, driv‐ ing error, natural wear.

– Replace clutch disc.

– Replace pressure plate.

– Inform customer.

Complaint Fault description Measure Clutch grabbing,

unit shaking.

♦ Clutch disc, pressure plate, fly‐

wheel - oily. Radial shaft seal of the engine or the gearbox de‐ fective. Grease on the contact surface through excess greas‐ ing of the hub.

♦ Clutch disc installed the wrong

way up.

♦ Flywheel depth too large or ex‐

cessive abrasion on the contact surface of the lining.

♦ Slave cylinder leaking. – Replace slave cylinder.

♦ Air in the system. – Bleed system, check brake fluid

♦ Engine does not run clean. – Check engine power, correct.

– Replace clutch disc.

– Clean contact surfaces of pres‐

sure plate and flywheel.

– Replace radial shaft seal, re‐

move excess grease from the drive shaft.

– Correct installation, check

clutch disc, replace if necessary.

– Assign the sealing flange via the

⇒ electronic catalogue of origi‐ nal parts .

– Inspect clutch disc and pressure

plate, replace if necessary.

level, check system for tight‐ ness.

– Replace defective part.

♦ Driving error, starting speed is

too low.

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

♦ Assembly bearing too soft,

knocked out.

♦ Clutch lining, contact surface of

pressure plate and flywheel oily (oil leakage from the clutch housing).

♦ Release bearing is tilted on the

guide bushing (seizured) (presses on one side onto the membrane spring of the pres‐ sure plate).

– Inform customer.

Electronic catalogue of original parts .

– Assign the assembly bracket via

the ⇒ Electronic catalogue of original parts .

– Check radial shaft seal of the

drive shaft for clutch or check crankshaft, if necessary re‐ place.

– Replace clutch disc, clean pres‐

sure plate and flywheel.

– Replace release bearing and

guide bushing.

– Check control elements and

bearing for control elements.

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Gearbox 02T - Edition 05.2014

Complaint Fault description Measure

♦ The contact surface of the pres‐

sure plate lifts off only unilater‐ ally due to the tilted release bearing.

♦ Pressure plate housing de‐

formed when installed. Contact surface of the pressure plate lifts off only unilaterally.

– Check the contact surface of the

clutch lining on the flywheel,

check pressure plate and mem‐

brane springs, replace pressure

plate if necessary.

– Replace release bearing and

guide bushing.

♦ Drive schaft too heavily greased

(traces of grease on the clutch disc, pressure plate and fly‐ wheel).

– Remove grease from pressure

plate and flywheel, replace if

damaged (traces of wear, traces

of overheating, grooves).

– 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.

Complaint Fault description Measure Acoustic knock »klack« when cou‐

pling.

♦ Carrier earth/drive shaft is ac‐

celerated with sudden coupling.

– Inform customer.

The drive shaft serration of the pinions in mesh knocks, this noise is increased for clutch discs with noise insulation as the damping reaches the stop.

Complaint Fault description Measure Noises in idle. ♦ Torsional damper spring kinked. – Replace clutch disc.

♦ Clutch disc fitted without pre‐

damper (idle rattling).

– Assign clutch disc via the ⇒

Electronic catalogue of original

parts .

♦ Pressure plate deformed, imbal‐

– Replace pressure plate.

ance.

♦ Irregular engine running. – Check engine power, correct if

necessary.

♦ Displacement of engine/gear‐

box too large (dowel sleeves

– Insert dowel sleeves before

gearbox has been fitted. missing).

♦ Intermediate plate grinds at fly‐

wheel.

– Insert intermediate plate on

sealing flange and push onto the

dowel sleeves.

3. Repairing clutch 75

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34 – Controls, housing

1 Shift mechanism

Installation position - selector mechanism ⇒ page 76 . Summary of components - Gearshift mechanism ⇒ page 78 . Summary of components - Gearshift knob with shift lever collar

⇒ page 79 .

Remove and install gearshift knob and shift lever collar (Fabia II, Roomster) ⇒ page 79 .

Remove and install gearshift knob and shift lever collar (Rapid)

⇒ page 80

Remove and install gearshift knob and shift lever collar (Rapid NH) ⇒ page 81 .

Summary of components - Shift lever and shift housing

⇒ page 82 .

Summary of components - Control cables ⇒ page 84 . Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)

⇒ page 87 .

Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) ⇒ page 89 .

Removing and installing shift mechanism (Rapid) ⇒ page 94 . Setting the shift mechanism ⇒ page 96 .

1.1 Installation position - selector mecha‐ nism

Arrow A - Shift movement Arrow B - Selector movement

76 Rep. gr.34 - Controls, housing

Page 81

A - Shift cable B - Selector cable C - Heat shield

❑ take off before removing

the shift mechanism

1 - Gearshift lever 2 - Reversing lever

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1. Shift mechanism 77

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1.2 Summary of components - Gearshift mechanism

Note

♦

If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

♦

Do not kink the control cables.

♦

Remove shift mechanism for replacing the control cables:

♦

Fabia II, Roomster, Rapid NH ⇒ page 89 .

♦

Rapid ⇒ page 94 .

I - Summary of components Gearshift knob with shift lever collar ⇒ page 79

II - Assembly overview - shift mechanism ⇒ page 82

III - Summary of components Control cables ⇒ page 84

78 Rep. gr.34 - Controls, housing

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1.3 Summary of components - Gearshift knob with shift lever collar

1 - Gearshift knob

❑ with collar ❑ it can be different in

shape on individual models

❑ It is not possible to sep‐

arate the gearshift knob from the collar

❑ always replace together

⇒ Electronic Catalogue of Original Parts

❑ removing and installing:

♦ Fabia II, Roomster

⇒ page 79

♦ Rapid ⇒ page 80 ♦ Rapid NH ⇒ page 81

❑ Plaque of gearshift lever

can be separated from the gearshift knob e.g. with a screwdriver (2011 ►)

2 - Centre console

1.4 Removing and installing gearshift knob

and shift lever collar (Fabia II, Room‐ ster)

Special tools and workshop equipment required ♦ Disassembly wedge - 3409- (2 pieces)

1. Shift mechanism 79

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– Lever off the collar with two disassembly wedges - 3409- out

of the surround of the centre console in -direction of arrow-.

– Pull the collar upwards over the gearshift knob.

– Turn securing mechanism -arrow A- in -direction of arrow B-

and pull off gearshift knob together with the collar. Install – Turn collar inside out. – Position the gearshift knob together with the collar and secure

with securing mechanism -arrow A- against the

-direction arrow B-.

When inserting the gearshift knob on the shift lever the gearshift knob must lock into the round slot of the gearshift lever.

1.5 Remove and install gearshift knob and

shift lever collar (Rapid)

Special tools and workshop equipment required ♦ Release tool - T30098- (2 pieces)

80 Rep. gr.34 - Controls, housing

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– Lever off the collar frame with the disassembly wedge -

T30098- out of the surround for the centre console in

-direction of arrow-.

– For this step, press on the frame -arrows- and at the same time

raise the frame. – Lift off the frame. – Pull the collar upwards over the gearshift knob.

– Turn securing mechanism -arrow A- in -direction of arrow B-

and pull off gearshift knob together with the collar. Install – Turn collar inside out. – Position the gearshift knob together with the collar and secure

with securing mechanism -arrow A- against the

-direction arrow B-.

When inserting the gearshift knob on the shift lever the gearshift knob must lock into the round slot of the gearshift lever.

– Fit the frame with its catch pegs into the rear part of the centre

console. – Lock the frame into the cover of the centre console in the front

part.

Gearbox 02T - Edition 05.2014

1.6 Remove and install gearshift knob and

shift lever collar (Rapid NH)

Special tools and workshop equipment required ♦ Release tool - T30098♦ Hose strap pliers , e.g. -V.A.G 1275 A– Lever the collar frame out of the centre console. To do so, fit

the release tool - T30098- between the collar frame and the

cover of the centre console in the middle of the front side

-arrow 1- and press it forwards in -direction of arrow 2-. – Lift off the frame. – Pull the collar upwards over the gearshift knob.

1. Shift mechanism 81

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– Open clamp -arrow- and pull off gearshift knob together with

the collar. Install – Turn collar inside out.

Note

When inserting the gearshift knob on the selector lever the gear‐ shift knob must be pressed in up to the stop.

– Position the gearshift knob together with the collar and secure

it with a new open warm-type clamp -arrow- by pressing it to‐

gether. – Fit the frame of the collar onto the pegs in the rear part of the

centre console. – Press the frame onto the cover of the centre console until it

locks into the pegs in the front part.

1.7 Summary of components - Shift lever and shift housing

Note

Grease bearing and friction surfaces with grease - G 000 450 02- .

82 Rep. gr.34 - Controls, housing

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1 - Lock washer

❑ removing and installing

⇒ page 84

2 - Pressure spring 3 - Gasket

❑ between shift housing

and body

❑ self-adhesive ❑ stuck onto the shift

housing 4 - Shift lever 5 - Damping

❑ removing and installing

⇒ page 84

6 - Shift housing 7 - Insulating washer

❑ must be present in the

round slot -arrow- at the

shift lever -Pos. 48 - Gasket

❑ replace ⇒ Electronic

Catalogue of Original

Parts 9 - Cover

❑ bend up tabs for remov‐

ing

❑ replace ⇒ Electronic

Catalogue of Original

Parts 10 - Bush 11 - Selector cable

❑ pressed onto selector angle plate ❑ slacken from selector angle plate within the shift mechanism ❑ press onto selector angle plate within the shift mechanism ❑ Fitting position ⇒ page 76 ❑ after installing set shift mechanism ⇒ page 96

12 - Shift cable

❑ pressed onto the shift lever guide ❑ slacken from the shift lever guide within the shift mechanism ❑ press onto the selector angle guide within the shift mechanism ❑ Fitting position ⇒ page 76 ❑ after installing set shift mechanism ⇒ page 96

13 - 23 Nm

❑ 4 pieces

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1. Shift mechanism 83

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Removing and installing lock washer – When removing and installing the circlip -A- pull the gearshift

lever in the -direction of the arrow A- while simultaneously pressing the spring down with a screwdriver up to the stop in the -direction of the arrow B-.

Note

♦

The mounting slot in shift lever for circlip must be visible.

♦

Release spring carefully.

Removing and installing damping -arrow– Press the pressure spring arm -A- as far as possible to the left

until it is located outside the damping -arrow-.

– Press the shift lever to the lift and pull off the damping.

• After installing the damping, the pressure spring arms -A- and

-B- must rest on the damping -Pfeil-.

1.8 Summary of components - Control cables

Note

Grease bearing and friction surfaces with grease - G 000 450 02- .

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1 - Shift cable

❑ slacken from the shift

lever guide within the

shift mechanism

❑ press onto the selector

angle guide within the

shift mechanism

❑ connect with cable lock

-Pos. 11-

❑ Fitting position

⇒ page 76

❑ after installing set shift

mechanism

⇒ page 96

2 - Selector cable

❑ slacken from selector

angle plate within the

shift mechanism

❑ press onto selector an‐

gle plate within the shift

mechanism

❑ at selector angle plate ❑ connect with cable lock

-Pos. 10-

❑ Fitting position

⇒ page 76

❑ after installing set shift

mechanism

⇒ page 96

3 - Bush 4 - Lock washer

❑ do not damage cables

when removing

❑ always replace ⇒ Elec‐

tronic Catalogue of Original Parts 5 - Shift housing 6 - Cable support

❑ can be made out of plastic or metal

7 - Bush

❑ for mounting of cable support to gearbox 8 - Spacer bush 9 - 20 Nm

❑ 3 pieces

❑ for cable support 10 - Cable lock

❑ for selector cable ⇒ page 86

❑ after installing set shift mechanism ⇒ page 96 11 - Cable lock

❑ for shift cable ⇒ page 86

❑ after installing set shift mechanism ⇒ page 96 12 - Lock washer

❑ always replace ⇒ Electronic Catalogue of Original Parts

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1. Shift mechanism 85

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❑ it is not necessary, if it is a plastic relay lever

13 - Bush

❑ it is not necessary, if it is a plastic relay lever

14 - Selector lever

❑ Fitting position ⇒ page 87 ❑ after installing set shift mechanism ⇒ page 96 ❑ as of 06.07 the relay level is made of plastic ❑ Removing and installing plastic relay lever together with cable lock ⇒ page 87 ❑ If the relay lever is made of plastic, neither the bushings -Pos. 13- nor the lock washer -Pos. 12- are

required

15 - Sliding shoe 16 - Gearshift lever

❑ with balancing weight ❑ Fitting position ⇒ page 87 ❑ after installing set shift mechanism ⇒ page 96

17 - 20 Nm

❑ always replace ⇒ Electronic Catalogue of Original Parts

18 - Lock washer

❑ always replace ⇒ Electronic Catalogue of Original Parts ❑ is not required on cable locks for selector cable at relay lever, if relay lever is made of plastic

Assign cable locks The holes in the cable locks have different diameters.

Cable lock Dimension “a” Shift cable at gearbox shift lever 10 mm

Selector cable at metal relay lever 8 mm Selector cable at plastic relay lever 10 mm

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Fitting location of gearbox shift lever – When inserting the gearbox shift lever, make sure that the

tooth opening -arrow A- is located above the interrupted spac‐ ing of the teeth -arrow B- for the gearshift shaft.

Fitting location of relay lever 1 - Gearbox shift lever -1- with balancing weight 2 - The relay lever -2- is inserted over the sliding shoe -arrow- into

the guiding nut of the gearbox shift lever

Gearbox 02T - Edition 05.2014

1.9 Plastic relay lever as of 06.07 (Fabia II,

Roomster, Rapid NH)

Removing

• Gearbox shift lever is located in the neutral position.

• Before removing the gearbox shift lever the cable lock must

be separated from the selector cable in order to avoid damage to the selector cable.

1. Shift mechanism 87

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– Pull forward the locking mechanism as far as the stop in

-direction of arrow 1-, then lock by turning to the left in

-direction of arrow 2-.

– Press the relay lever towards the front in the

-direction of arrow 3-.

Relay lever with a catch – Carefully press down the pin detent -arrow 1- as far as the

stop.

– Carefully take the relay lever -A- together with the cable lock

-B- out of its bearing point.

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Relay lever with clip – Remove clip -arrow°1-. – Carefully take the relay lever together with the cable lock out

of its bearing point.

Continued for all versions

• Only remove cable lock on removed relay lever ⇒ page 89 . Install

Note

Before installing, grease bearing points and friction surfaces with grease - G 000 450 02- .

– Press cable lock onto the relay lever ⇒ page 89 . – Insert relay lever together with cable lock up to the stop in its

bearing point.

• The cable lock must be located behind the catch -arrow 2-.

• The pin detent or the clip -arrow 1- secures the relay lever.

Gearbox 02T - Edition 05.2014

Lever off cable lock for selector cable from plastic relay lever

• Relay lever removed. – Position a cross-head screwdriver -A- between bushing -B-

and relay lever.

Press on cable lock

• Relay lever removed.

• The cable lock must only be pressed onto the bushing

-arrow-.

• Cable lock must move freely on relay lever.

• The cable lock must be located behind the pin detent

⇒ page 89 .

1.10 Remove and install shift mechanism

(Fabia II, Roomster, Rapid NH)

Special tools and workshop equipment required

1. Shift mechanism 89

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♦ Disassembly wedge - 3409- (2 pieces) (Fabia II, Roomster) ♦ Release tool - T30098- (Rapid NH) ♦ Grease - G 000 450 02-

1.10.1 Removing

Note

If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical 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 . – Remove circlip -3- for shift cable from gearbox shift lever -1-. Metal relay lever – Remove circlip -4- for selector cable from relay lever -2-. – Remove selector cable and shift cable from the studs. Plastic relay lever – Pull off shift cable from the stud. – Remove relay lever together with cable lock ⇒ page 87 . Continued for all vehicles

– Disconnect the Bowden cable support from gearbox

-arrows-. – Remove gearshift knob and shift lever collar: ♦ Fabia II and Roomster ⇒ page 79 . ♦ Rapid NH ⇒ page 81 . – Remove the centre console cover ⇒ Body Work; Rep. gr. 68 . – If present, remove noise insulation from shift housing.

– Unscrew fixing nuts -arrows- attaching the shift housing. – Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 .

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– Remove underbody cover on right and left (if present)

-arrows-.

– Remove tunnel bridge -arrows-. Vehicles Rapid NH – Remove bracket for retaining straps of middle silencer from

the body. Continued for all vehicles – Unhook rear silencer in such a way that it does not come in

contact with the rear axle.

Gearbox 02T - Edition 05.2014

– Remove heat shield -arrows-. – Swivel shift housing down and remove with control cables.

1.10.2 Install

Installation is carried out in the reverse order. However, pay at‐ tention to the following:

1. Shift mechanism 91

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– Always replace lock washers -3- and -4- after each disassem‐

bly ⇒ Electronic Catalogue of Original Parts .

– Secure the shift cable with the lock washer -3- and the selector

cable with the lock washer -4- (for metal relay lever). Cable lock with plastic relay lever – The relay lever and the cable lock must be mounted together

⇒ page 87 .

– Insert the selector cable into the cable lock. Continued for all gearshift mechanisms – Align shift housing parallel to vehicle body.

• The distance to the vehicle body must be the same on both

sides. – Assemble exhaust system free of stress and attach tunnel

bridges ⇒ Engine; Rep. gr. 26 . – Install the noise insulation ⇒ Body Work; Rep. gr. 50 . – Setting the shift mechanism ⇒ page 96 . – Install air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr.

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

notes in the ⇒ Electrical System; Rep. gr. 27 .

92 Rep. gr.34 - Controls, housing

Page 97

Tightening torques

Components Tightening torque Underbody cover 2 Nm

Shift housing to body ⇒ page 82 Cable support to gearbox ⇒ page 84 Tunnel bridge ⇒ Engine; Rep. gr. 26 Bracket for the exhaust system ⇒ Engine; Rep. gr. 26

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1.11 Removing and installing shift mecha‐

nism (Rapid)

Special tools and workshop equipment required ♦ Release tool - T30098- (2 pieces) ♦ Grease - G 000 450 02-

1.11.1 Removing

Note

After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 . – Remove air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep.

gr. 24 . – Remove circlip -3- for shift cable from gearbox shift lever -1-. – Pull off shift cable from the stud -arrow-. – Remove circlip -4- for the selector cable from relay lever -2-. – Pull off the selector cable from the stud -arrow-.

– Remove Bowden cable support -arrows-. – Remove gearshift knob and shift lever collar ⇒ page 80 . – Remove the centre console ⇒ Body Work; Rep. gr. 68 . – If present, remove noise insulation from shift housing.

– Unscrew nuts -arrows- attaching the shift housing. – Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 .

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– Remove underbody cover on right and left (if present)

-arrows-.

– Remove tunnel bridge -A- -arrows-. – Unhook rear silencer in such a way that it does not come in

contact with the rear axle.

Gearbox 02T - Edition 05.2014

– Remove heat shield -arrows-. – Swivel shift housing down and remove with control cables.

1.11.2 Install

Installation is performed in the reverse order, pay attention to the following points:

The holes in the cable locks have different diameters ⇒ page 84

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– 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-.

– Always replace lock washers -3- and -4- after each disassem‐

bly ⇒ Electronic Catalogue of Original Parts . – Secure the shift cable with the lock washer -3- and the selector

cable (for metal relay lever) with the lock washer -4-. – Align shift housing parallel to vehicle body.

• The distance to the vehicle body must be the same on both

sides. – Assemble exhaust system free of stress and attach tunnel

bridges ⇒ Engine; Rep. gr. 26 . – If present, position the noise insulation on the shift housing. – Install centre console ⇒ Body Work; Rep. gr. 68 . – Setting the shift mechanism ⇒ page 96 . – Install air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr.

24 . – Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .

Note

After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System; Rep. gr. 27 .

Tightening torques

Components Tightening torque Underbody cover 2 Nm

Shift housing to body ⇒ page 82 Cable support to gearbox ⇒ page 84 Tunnel bridge ⇒ Engine; Rep. gr. 26 Bracket for pre-exhaust pipe ⇒ Engine; Rep. gr. 26

1.12 Setting the shift mechanism

Special tools and workshop equipment required ♦ Rig pin - T10027A♦ Disassembly wedge - 3409- (2 pieces - Fabia II, Roomster) ♦ Release tool - T30098- (2 pieces - Rapid, 1 piece - Rapid NH)

Note

The following are required for correct setting of the shift mecha‐ nism:

• Gearbox, clutch and clutch control in perfect condition.

• Selector mechanism must move freely.

• Control elements and transmission elements of the shift mech‐

anism are in perfect condition.

SKODA Fabia II 2007, Fabia II 2009, Fabia II 2011, Rapid 2011, Rapid NH 2013 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Identification of the gearbox

1.1 Identification characters, aggregate assignment, ratios, filling capacities (Fabia II)

1.2 Identification characters, aggregate assignment, ratios, filling capacities (Roomster)

1.3 Identification characters, aggregate assignment, ratios, filling capacities (Rapid)

1.4 Identification characters, aggregate assignment, ratios, filling capacities (Rapid NH)

2 Overview of Transmission System

2.1 Designation of components and transmission ratio

3 General repair instructions

30 – Clutch

1 Clutch control

1.4 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)

1.6 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)

1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

1.7.1 Removing and installing clutch pedal switch - F36-

1.7.2 Removing and installing crash strut

1.8 Summary of components - Foot controls (Rapid)

1.8.1 Removing and installing clutch pedal switch - F36-

1.9.1 Removing

1.9.2 Install

1.10 Removing and installing the bracket with the master cylinder (Rapid 2011 ►)

1.10.1 Removing

1.10.2 Install

1.11 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

1.15 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH)

1.17 Summary of components - Hydraulic (Rapid 2011 ►)

1.18 Check hydraulic clutch control

1.19.1 Removing

1.19.2 Install

1.21.1 Removing

1.21.2 Install

1.22 Bleeding the clutch control

3 Repairing clutch

34 – Controls, housing

1 Shift mechanism

Installation position - selector mechanism ⇒ page 76 . Summary of components - Gearshift mechanism ⇒ page 78 . Summary of components - Gearshift knob with shift lever collar

1.2 Summary of components - Gearshift mechanism

1.3 Summary of components - Gearshift knob with shift lever collar

1.7 Summary of components - Shift lever and shift housing

1.8 Summary of components - Control cables

1.10.1 Removing

1.10.2 Install

1.11.1 Removing

1.11.2 Install

1.12 Setting the shift mechanism