SKODA Fabia II 2007, Fabia II 2009, Fabia II 2011, Rapid 2011, Rapid India 2011 Workshop Manual

Service

Workshop Manual

Fabia II 2007 ➤ , Fabia II 2009 ➤ ,

F
Rapid India 2011 ➤ , Rapid NH 2013 ➤ ,
Roomster 2006 ➤

abia II 2011 ➤ , Rapid 2011 ➤ ,

Gearbox 02R

Edition 08.2014

Service Department. Technical Information

Service

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

R

ep ai r Gr ou p

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

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

Gearbox 02R - Edition 08.2014

Contents

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

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

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

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 Identification characters, aggregate assignment (Fabia II) . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Identification characters, aggregate assignment (Roomster) . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Identification characters, aggregate assignment (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Identification characters, aggregate assignment (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . 3

2.5 Filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.6 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.1 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 10

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

►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 16

1.5 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH) . . 17

1.6 Summary of components - Foot controls (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.8 Removing and installing the bracket with the master cylinder (Rapid) . . . . . . . . . . . . . . . . 30

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

2011 ►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.10 Removing and installing the bracket without the master cylinder (Rapid) . . . . . . . . . . . . . . 34

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

Roomster 2011 ►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) . . . . 38

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

2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) . . . . . . . . . . . . 41

1.15 Summary of components - Hydraulic (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.16 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.17 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . 48

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

►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.19 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.20 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.1 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 60

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1.2 Summary of components of the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.3 Summary of components - gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.4 Separating collar from gearshift lever (Fabia II, Roomster) . . . . . . . . . . . . . . . . . . . . . . . . 69

1.5 Separating collar from gearshift lever (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Contents i

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

1.6 Remove and install gearshift knob and shift lever collar (Rapid NH) . . . . . . . . . . . . . . . . . . 72

1.7 Summary of components - Shift lever and shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.8 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . . . . . . . 77

1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . 79

1.11 Removing and installing shift mechanism (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.12 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.1 Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.2 Removing gearbox (Fabia II 2011 ►; Roomster 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.3 Removing gearbox (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

2.4 Removing gearbox (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

2.5 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

2.6 Tightening torques (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2.7 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

3 Check gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4.1 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 130

4.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 131

4.5 Removing and installing the drive shaft, output shaft, differential gear and shift forks . . . . 133

4.6 Mounting sequence - Removing and installing gearbox housing cover and 5th gear . . . . 134

4.7 Mounting sequence - completely disassembling and assembling the gearbox . . . . . . . . . . 139

5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6 Repairing the gearshift mechanism on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 155

6.1 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft

can be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

6.2 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft

cannot be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

7 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.2 Setting drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

2.2 Setting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

3.1 Disassembling and assembling the reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1 Replacing the flange shaft gasket rings (gearbox assembled) . . . . . . . . . . . . . . . . . . . . . . 191

1.1 Replacing the left flange shaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1.2 Replace gasket ring for right flange shaft (gasket ring and bushing are one component) . . 193

2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

2.1 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

3 Setting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

ii Contents

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

00 – Technical data

1 Identification of the gearbox

(SRL000728; Edition 08.2014)

⇒ “1.1 Identification of the gearbox”, page 1

1.1 Identification of the gearbox

Location on the gearbox
Identification characters and production date -arrow 1-.
Identification of gearbox 02R -arrow 2-.

Gearbox 02R - Edition 08.2014

Identification characters and production date of the gearbox

Example: JDE 18 02 7

Identification of gearbox 02R -arrow 2-.

I I I I

Identifica‐

tion char‐

acters

Day Month Manufacturing

year (2007)

1. Identification of the gearbox 1

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

2 Technical data

⇒ “2.1 Identification characters, aggregate assignment (Fabia II)”,
page 2

⇒ “2.2 Identification characters, aggregate assignment (Room‐
ster)”, page 3

⇒ “2.3 Identification characters, aggregate assignment (Rapid)”,
page 3

⇒ “2.4 Identification characters, aggregate assignment (Rapid
NH)”, page 3

⇒ “2.5 Filling capacity”, page 4
⇒ “2.6 Calculation of gear ratios”, page 4

2.1 Identification characters, aggregate assignment (Fabia II)

Manual gearbox 5 speed 02R
Manufactured from

through
Identification characters JCZ JDE JDD
Assignment: Engine 1.4 ltr./59 kW TDI

02.07

03.10

02.07

03.10

03.08

03.10

Manual gearbox 5 speed 02R
Manufactured from

through
Identification characters JDA JXY
Assignment: Engine 1.9 ltr./77 kW TDI 1.9 ltr./77 kW TDI

Manual gearbox 5 speed 02R
Manufactured from

through
Identification characters KFK, MZL MAL MNY
Assignment: Engine 1.6 ltr./55 kW TDI CR

1.6 ltr./66 kW TDI CR

1.6 ltr./77 kW TDI CR

Manual gearbox 5 speed 02R
Manufactured from

through
Identification characters MUW MZR
Assignment: Engine 1.2 ltr./55 kW TDI CR

04.07

04.07

03.10 03.10

09.10

10.10

04.07

03.10

10.10

1.2 ltr./55 kW TDI CR

11.10

05.10

10.10

Manual gearbox 5 speed 02R
Manufactured from

through
Identification characters MZK MZN MZM
Assignment: Engine 1.2 ltr./55 kW TDI CR 1.6 ltr./66 kW TDI CR

11.10 11.10 11.11

2 Rep. gr.00 - Technical data

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

Gearbox 02R - Edition 08.2014

2.2 Identification characters, aggregate assignment (Roomster)

Manual gearbox 5 speed 02R
Identification characters HZP JEP

Manufac‐
tured

Assignment Engine 1.9 ltr./77 kW TDI

Manual gearbox 5 speed 02R
Identification characters JXZ JDE

Manufac‐
tured

Assignment Engine 1.9 ltr./77 kW TDI 1.4 ltr./59 kW TDI

Manual gearbox 5 speed 02R
Identification characters MQC MQD

Manufac‐
tured

Assignment Engine 1.2 ltr./55 kW TDI CR

from

through

from

through

from

through

03.06

05.06

01.07

03.10

03.10

10.10

05.06

12.06

05.06

03.10

05.10

10.10

Manual gearbox 5 speed 02R
Identification characters MZP MZQ

Manufac‐
tured

Assignment Engine 1.2 ltr./55 kW TDI CR

Manual gearbox 5 speed 02R
Identification characters KFK, MZL

Manufac‐
tured

Assignment Engine 1.6 ltr./55 kW TDI CR

from

through

from

through

11.10 11.10

03.10

1.6 ltr./66 kW TDI CR

1.6 ltr./77 kW TDI CR

2.3 Identification characters, aggregate assignment (Rapid)

Manual gearbox 5 speed 02R
Identification characters MZS MZS QXQ

Manufactured from

through

Assignment: Engine 1.6 ltr./77 kW TDI CR

09.11 08.14

08.15

08.15

2.4 Identification characters, aggregate assignment (Rapid NH)

Manual gearbox 5 speed 02R

2. Technical data 3

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Manual gearbox 5 speed 02R
Identification characters MZL MZM MZS

Manufactured from

through
Assignment: Engine 1.6 ltr./77 kW TDI CR

07.12 07.12 07.12

2.5 Filling capacity

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

2.6 Calculation of gear ratios

Example

Drive wheel ZG1 = 46 ZA1 = 24
Output gear ZG2 = 33 ZA2 = 70

i = ZG2 : ZG1

iG = Ratio of a gear = ZG2 : ZG1 = 33 : 46 = 0,717

iA = Ratio of the final drive = ZA2 : ZA1 = 70 : 24 = 2,917

i

= Total ratio = iG x iA = 0.717 x 2.917 = 2.091

total

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

1)

5th gear Final drive

4 Rep. gr.00 - Technical data

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

Gearbox 02R - Edition 08.2014

3 Overview of Transmission System

⇒ “3.1 Designation of components and transmission ratio”,
page 5

3.1 Designation of components and transmission ratio

Note

The -arrows- point in 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

❑ for vehicles without ABS

3. Overview of Transmission System 5

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

4 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 summarised here. They apply for this
particular workshop manual.

Gearbox
♦ Thoroughly clean the connection points and their surroundings

before releasing.

♦ Bolts and other attachments should have a classification in the

⇒ Electronic Catalogue of Original Parts .

♦ When installing the manual gearbox, ensure the dowel

sleeves are correctly located between the engine and gear‐
box.

♦ When installing mounts as well as waxed components, the

contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.

♦ When replacing the gearbox, inspect the gearbox oil level and

top up with oil if necessary

⇒ “3 Check gear oil level”, page 127 .

♦ Filling capacity, Fabia II

⇒ “2.1 Identification characters, aggregate assignment (Fabia
II)”, page 2

♦ Filling capacity, Roomster

⇒ “2.2 Identification characters, aggregate assignment
(Roomster)”, page 3

♦ Filling capacity, Rapid

⇒ “2.3 Identification characters, aggregate assignment (Rap‐
id)”, page 3

♦ Filling capacity, Rapid NH

⇒ “2.4 Identification characters, aggregate assignment (Rapid

NH)”, page 3

♦ Oil specification ⇒ Electronic Catalogue of Original Parts .
Sealant
♦ Thoroughly clean the contact surfaces of the housing before

applying the silicone sealant.
♦ Apply sealant AMV 188 200 03 evenly and not too thick.

6 Rep. gr.00 - Technical data

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

O-rings, gasket rings, gaskets
♦ Replace O-rings, gasket rings and gaskets ⇒ Electronic Cata‐

logue of Original Parts .

♦ After removing gaskets, check the contact surface in the hous‐

ing or shaft for burrs or damage which occured during the
assembly.

♦ Shaft seals - before mounting lightly oil at outside diameter

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

♦ The open side of the shaft seals is turned towards the fluid to

be sealed.

♦ Press in new shaft seal in such a way that the sealing lip is not

located on the same point as the sealing lip of the old seal (use
tolerance for insertion depth).

♦ Before inserting lightly oil the O-rings, in order to prevent the

rings being squashed during installation.

♦ Inspect the oil level after replacing the gaskets and gasket

rings, top up oil if necessary

⇒ “3 Check gear oil level”, page 127 .

Locking elements

Gearbox 02R - Edition 08.2014

♦ Do not over-tension the circlips.
♦ Always replace damaged or over-tensioned circlips ⇒ Elec‐

tronic Catalogue of Original Parts .
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: Slot -A- longitudinal to power

flow -arrow-.

4. General repair instructions 7

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Nuts and bolts
♦ Slacken the bolts and nuts against the tightening sequence.
♦ Slacken and tighten nuts and bolts for attaching covers and

housings without tightening sequence diagonally across in

stages.
♦ Replace the self-locking screws and nuts.
♦ Specified torques given are for unlubricated nuts, bolts and

screws.
♦ Clean the threaded holes into which self-locking screws or

screws with locking agent were screwed in (using e.g. a screw-

tap). Otherwise there is a danger of bolts shearing when

subsequently being removed.
♦ It is important to ensure at all bolted connections that the con‐

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

being installed, should this be necessary.
Bearings
♦ Insert moist all bearings into the gearbox with gear oil.
♦ Before installing, heat the inner rings of the bearing on a heat‐

ing plate or with the induction heater unit - VAS 6414- 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 mix up the outer and inner races of bearings of the

same size.
♦ Always jointly replace tapered-roller bearings on the same

shaft and use products of the same manufacturer.
♦ Position needle bearing with the lettered side (thicker end) to‐

wards the drift pin.
Shims

♦ Measure shims at several points with a micrometer. Different

tolerances allow to measure the required thickness for each

washer very precisely.
♦ Check for burrs and damage.
♦ Install only adjusting washers which are in perfect condition.
Synchronizer rings

8 Rep. gr.00 - Technical data

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

♦ 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 with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the induction heater

unit - VAS 6414- to approx. 100°C before pressing on.
♦ The temperature can be checked with a temperature measur‐

ing instrument.
♦ Check fitting position.
Sliding gears
♦ Check 1st to 5th gear sliding gears after assembly for low axial

play or smooth operation.
Clutch control
♦ When removing gearbox, remove slave cylinder, do not de‐

tach the tube-hose line.
♦ 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 (further measures

⇒ “1.16 Check hydraulic clutch control”, page 47 ).

♦ 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 02R - Edition 08.2014

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).

4. General repair instructions 9

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

30 – Clutch

1 Clutch control

⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;
Roomster 2006 ►)”, page 10

⇒ “1.2 Removing and installing the crash strut for the clutch pedal
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14

⇒ “1.3 Removing and installing the over-centre helper spring (Fa‐
bia II 2007 ►; Roomster 2006 ►)”, page 14

⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007 ►;
Roomster 2006 ►)”, page 16

⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 17

⇒ “1.6 Summary of components - Foot controls (Rapid) ”,
page 25

⇒ “1.7 Removing and installing the bracket with the master cylin‐
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27

⇒ “1.8 Removing and installing the bracket with the master cylin‐
der (Rapid) ”, page 30

⇒ “1.9 Removing and installing the bracket without the master
cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”,
page 32

⇒ “1.10 Removing and installing the bracket without the master
cylinder (Rapid) ”, page 34

⇒ “1.11 Removing and installing the clutch pedal with the over­centre helper spring (Fabia II 2011 ►; Roomster 2011 ►; Rapid
NH)”, page 36

⇒ “1.12 Removing and installing the clutch pedal with the over­centre helper spring (Rapid) ”, page 38

⇒ “1.13 Removing and installing the clutch pedal with the tension
spring (Fabia II 2011 ►; Roomster 2011 ►)”, page 39

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Room‐
ster ►; Rapid NH) ”, page 41

⇒ “1.15 Summary of components - Hydraulic (Rapid) ”,
page 44

⇒ “1.16 Check hydraulic clutch control”, page 47
⇒ “1.17 Removing and installing the master cylinder (Fabia II 2007

►; Roomster 2006 ►)”, page 48
⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011

►; Roomster 2011 ►; Rapid 2011 ►; Rapid NH)”, page 50
⇒ “1.19 Removing and installing the slave cylinder”, page 51
⇒ “1.20 Bleeding the clutch control ”, page 54

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

Special tools and workshop equipment required
♦ Polycarbamide grease - G 052 142 A2-

10 Rep. gr.30 - Clutch

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

Gearbox 02R - Edition 08.2014

Note

♦

Summary of components - Hydraulics

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41 .

♦

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

♦

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

♦

Prior to working on the foot controls remove the storage area on the driver's side ⇒ Body Work; Rep. gr.
70 .

1 - Front wall

❑ with mount for bearing

bracket and master cyl‐
inder

2 - Gasket

❑ always replace ⇒ Elec‐

tronic Catalogue of
Original Parts

3 - Bearing bracket

❑ for attaching clutch ped‐

al

4 - Screw
5 - Gas/brake foot controls
6 - 25 Nm

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

tronic Catalogue of
Original Parts

7 - Clutch pedal switch - F36-

❑ Difference between

clutch pedal switch

⇒ page 13

❑ Assignment ⇒ Electron‐

ic Catalogue of Original
Parts

❑ Removing and installing

⇒ “1.1.1 removing and
installing, setting angu‐
lar clutch pedal switch
F36 ”, page 13 angular

clutch pedal switch

❑ Removing and installing

⇒ “1.1.2 removing and installing, setting cylindrical clutch pedal switch F36 ”, page 13 cylindrical clutch

pedal switch

8 - Over-centre helper spring

❑ removing and installing

⇒ “1.3 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)”, page
14

1. Clutch control 11

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

9 - Bushing
10 - Bearing bolt
11 - Clutch pedal

❑ removing and installing

⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 16

12 - Support

❑ only replace if the master cylinder has been removed
❑ removing and installing

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41

13 - 25 Nm

❑ self-locking
❑ for master cylinder to front wall
❑ always replace ⇒ Electronic Catalogue of Original Parts

14 - Master cylinder

❑ removing and installing

⇒ “1.17 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►)”, page 48

15 - Clamp

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

16 - Supply hose

❑ out of plastic ⇒ page 12

17 - Bearing

❑ for over-centre helper spring
❑ insert in bearing bracket
❑ always replace ⇒ Electronic Catalogue of Original Parts
❑ Fitting position: Peg -arrow- clips into the recess on the master cylinder

18 - Screw

❑ for pedal stop on bracket

19 - Pedal stop

❑ screw onto bracket with screw Pos.18 with the master cylinder installed

20 - 25 Nm

❑ self-locking
❑ always replace ⇒ Electronic Catalogue of Original Parts

Plastic return hose -1-

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

12 Rep. gr.30 - Clutch

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

Difference between clutch pedal switches - F36­♦ -A- Clutch pedal switch with angular housing
Removing and installing

⇒ “1.1.1 removing and installing, setting angular clutch pedal
switch F36 ”, page 13 .

♦ -B- Clutch pedal switch with cylindrical housing
Removing and installing

⇒ “1.1.2 removing and installing, setting cylindrical clutch pedal
switch F36 ”, page 13 .

1.1.1 removing and installing, setting angular clutch pedal switch - F36-

Gearbox 02R - Edition 08.2014

Note

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

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
– Pull out the tappet of the clutch pedal switch up to the stop.
– Press down the clutch pedal as far as possible.
– Insert clutch pedal switch into the support and turn switch by

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 .

1.1.2 removing and installing, setting cylindri‐

cal 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.

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

Rep. gr. 70 .

1. Clutch control 13

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– 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

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

Installing and setting

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

-3- fully.

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

ing, 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 .

1.2 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- and remove crash strut.
Install
Installation is carried out in the reverse order.

Tightening torque

Crash strut to steering column 9 Nm

1.3 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 A2-

14 Rep. gr.30 - Clutch

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

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

Rep. gr. 70 .

– Remove crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

– Remove clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-, if provided.

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

– Pull clutch pedal slightly into the passenger compartment.
– Insert pliers - T10005- in the clutch pedal recesses.
– Press together both sides of the support inwards using the pli‐

ers - T10005- -arrows- and separate the clutch pedal from the
master cylinder.

Gearbox 02R - Edition 08.2014

– Press the over-centre helper spring towards the front wall

-in direction of arrow- and remove it downwards.

Install

• Check whether the bearing -arrow 1- for the over-centre helper
spring is inserted in the bracket.

Fitting position:
The peg of the bearing is located in the recess of the master cyl‐

inder -arrow 2-.
– First of all, insert the over-centre helper spring in the rear

bearing.

1. Clutch control 15

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Then press the over-centre helper spring onto the centering

pin of the clutch pedal -arrow-.

– Position the clutch pedal with the master cylinder

⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007
►; Roomster 2006 ►)”, page 16 .

– Install clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-.

– Install crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

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

gr. 70 .

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

Rep. gr. 70 .

– Remove crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

– Remove clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-, if provided.

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

– Pull clutch pedal slightly into the passenger compartment.
– Insert pliers - T10005- in the clutch pedal recesses.
– Press together both sides of the support inwards using the pli‐

ers - T10005- -arrows- and separate the clutch pedal from the
master cylinder.

– Removing the over-centre helper spring

⇒ “1.3 Removing and installing the over-centre helper spring
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

– Put steering wheel in the lower position.

– Unscrew nut -A- and pull out screw from bracket (to facilitate

pulling out the screw, turn the steering wheel to the corre‐

sponding position).
– Remove clutch pedal.
Install
Installation is performed in the reverse order, pay attention to the

following points:

• Always replace self-locking nut ⇒ Electronic Catalogue of

Original Parts .

16 Rep. gr.30 - Clutch

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

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

the master cylinder.

– To click in the support, press the clutch pedal towards the front

wall in -direction of arrow-. While doing so, make sure it catch‐
es correctly in the support.

– Install clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-.

– Install crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

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

gr. 70 .

Tightening torque

Gearbox 02R - Edition 08.2014

Clutch pedal to bracket

1)

Replace self-locking nut.

1)

⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;

Roomster 2006 ►)”, page 10 -Position 20-

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

Note

♦

Summary of components - Hydraulics

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41 .

♦

After the battery earth strap is disconnected and re-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. Clutch control 17

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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

⇒ “1.7 Removing and in‐
stalling the bracket with
the master cylinder (Fa‐
bia II 2011 ►; Roomster
2011 ►; Rapid NH)”,
page 27

❑ removing and installing

without master cylinder

⇒ “1.9 Removing and in‐
stalling the bracket with‐
out the master cylinder
(Fabia II 2011 ►; Room‐
ster 2011 ►; Rapid NH)”,
page 32

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 ⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”, page 20

6 - Crash strut

❑ is attached to the steering column
❑ different versions ⇒ electronic catalogue of original parts
❑ removing and installing ⇒ “1.5.2 Removing and installing crash strut”, page 21

7 - Screw

❑ for crash strut Pos. 6 at steering column

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

❑ for the clutch pedal
9 - Bracket axle

❑ 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

18 Rep. gr.30 - Clutch

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

Gearbox 02R - Edition 08.2014

❑ removing and installing

⇒ “1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 36

11 - Clutch pedal

❑ removing and installing with over-centre helper spring

⇒ “1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 36

❑ with tension springs (Fabia II 2011 ►; Roomster 2011 ►)

⇒ “1.13 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011

►)”, page 39

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 20
14 - Cap
15 - Support

❑ only replace if the master cylinder has been removed

❑ removing and installing

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41

16 - Master cylinder

❑ removing and installing

⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid 2011 ►;
Rapid NH)”, page 50

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 44
20 - Clutch position sender - G476-

❑ for vehicles with start-stop system

❑ Assign components via the ⇒ Electronic catalogue of original parts

❑ removing ⇒ page 28

❑ installing ⇒ page 30

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

1. Clutch control 19

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

Gearbox 02R - Edition 08.2014

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

2nd spring coil -arrows-.

1.5.1 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- .
– Turn the clutch pedal switch at the bracket 45° in

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

Vehicles Rapid NH

Note

To improve access to the clutch pedal switch - F36- the securing
nuts for the bearing bracket for the clutch pedal can be removed
and the bearing bracket removed in part

⇒ “1.9 Removing and installing the bracket without the master
cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”,
page 32 .

Continued for all vehicles
Install

20 Rep. gr.30 - Clutch

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

• 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 .

Gearbox 02R - Edition 08.2014

1.5.2 Removing and installing crash strut

There are two different versions of crash strut for clutch pedal
which can be fitted to the steering column.

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.

1. Clutch control 21

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Tightening torque

Crash strut to steering column (2 screws) 9 Nm

22

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

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

Rep. gr. 70 .

– Unscrew plug -arrow-.
– Unhook the crash strut from the steering column.
Install
Installation is carried out in the reverse order.

Gearbox 02R - Edition 08.2014

23

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Tightening torque

Crash strut to steering column (1 screw) 20 Nm

24

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

Gearbox 02R - Edition 08.2014

1.6 Summary of components - Foot controls (Rapid)

Note

♦

Summary of components - Hydraulics ⇒ “1.15 Summary of components - Hydraulic (Rapid) ”, page 44 .

♦

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

⇒ “1.8 Removing and in‐
stalling the bracket with
the master cylinder
(Rapid) ”, page 30

❑ removing and installing

without master cylinder

⇒ “1.10 Removing and
installing the bracket
without the master cylin‐
der (Rapid) ”,
page 34

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

⇒ “1.6.1 Removing and
installing clutch pedal switch F36 ”, page 26

6 - Stop

❑ for the clutch pedal

7 - Bracket axle

❑ always replace ⇒ Electronic Catalogue of Original Parts

8 - Over-centre helper spring

❑ removing and installing

⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”,
page 38

25

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

9 - Clutch pedal

❑ removing and installing with over-centre helper spring

⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”,

page 38

10 - Bushing
11 - Cap
12 - Support

❑ only replace if the master cylinder has been removed
❑ removing and installing ⇒ “1.15 Summary of components - Hydraulic (Rapid) ”, page 44

13 - Master cylinder

❑ removing and installing

⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid 2011 ►;

Rapid NH)”, page 50

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 26

Plastic return hose -1-

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

1.6.1 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.

26

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

– 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 .

Gearbox 02R - Edition 08.2014

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 Removing and installing the bracket with

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

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

1.7.1 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 ⇒ Engine; Rep. gr. 23 .

27

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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

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

♦

When performing the following work, make sure that no brake

fluid comes into contact with the frame side rail or the gearbox.

If this is the case, these points must be cleaned thoroughly.

– 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.

– 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 connected electrical

plug connection from the master cylinder.
Continued for all vehicles

Note

When working in the footwell, protect the floor covering with cloths
from escaping brake fluid.

– Removing the footwell vent ⇒ Heating and Air Conditioning;

Rep. gr. 87 .
– If present, remove crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

– Put steering wheel in the highest position.

28

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

– Remove clutch pedal switch - F36- -1-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20 .

– 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-.

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

Gearbox 02R - Edition 08.2014

1.7.2 Install

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

Note

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

– Install clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20

– If present, install the crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

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

gr. 87 .

29

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Vehicles with start-stop system
– Insert the clutch position sender - G476- with connected elec‐

trical plug connection 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 clutch mechanism

⇒ “1.20 Bleeding the clutch control ”, page 54 .

– If removed, install the engine control unit at the front wall ⇒

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

Tightening torques

Bracket/clutch pedal to front wall

Master cylinder to front wall

1)

Replace self-locking nut.

1)

1)

⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;

Roomster 2011 ►; Rapid NH)”, page 17 -Position 4-

⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;

Roomster 2011 ►; Rapid NH)”, page 17 -Position 4-

1.8 Removing and installing the bracket with

the master cylinder (Rapid)

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

1.8.1 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.

30

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

– 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.

♦

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

– 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 working in the footwell, protect the floor carpet with cloths
from escaping brake fluid.

Gearbox 02R - Edition 08.2014

– 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-.

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

1.8.2 Install

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

31

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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 clutch mechanism

⇒ “1.20 Bleeding the clutch control ”, page 54 .

Tightening torques

Bracket/clutch pedal to front wall

Master cylinder to front wall

1)

Replace self-locking nut.

1)

1)

⇒ “1.6 Summary of components - Foot controls (Rapid) ”, page 25

⇒ “1.6 Summary of components - Foot controls (Rapid) ”, page 25

1.9 Removing and installing the bracket

without the master cylinder (Fabia II
2011 ►; Roomster 2011 ►; Rapid NH)

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

Rep. gr. 87 .

32

-Position 4-

-Position 4-

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

– If present, remove crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

– Put steering wheel in the highest position.
– Remove clutch pedal switch - F36- -1-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,

page 20 .

– 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-.

– 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-.

Gearbox 02R - Edition 08.2014

– 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:

33

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Note

Replace 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 clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20

– If present, install the crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

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

gr. 87 .

1.10 Removing and installing the bracket without the master cylinder (Rapid)

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-.

34

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

– 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 02R - Edition 08.2014

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 .

35

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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

Note

♦

Install the clutch pedal with a new bearing axle.

♦

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

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

– Remove clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,

page 20 .

– Subsequently release the actuating rod of the master cylinder.
– Pull clutch pedal slightly into the passenger compartment.
– Press both sides of the support inwards using the pliers -

T10005- -arrows-

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

-in direction of arrow-, so that the pegs are positioned hori‐

zontally.

-1- = Allan key, wrench size 8 mm.
The catches -A- are destroyed.
– 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 axle.

36

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

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

into the support -A- in the bracket next to the body of the mas‐
ter 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-.

Gearbox 02R - Edition 08.2014

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 clutch pedal slightly and insert a new bearing bolt.
– Position the pegs -A- horizontally.
– Turn the bearing bolt for the clutch pedal to the left

-in direction of arrow-, so that the pegs are positioned hori‐
zontally.

– Turn the bearing bolt to the right -in direction of arrow-, so that

the pegs are positioned vertically.

-1- = 8 mm Allan key.

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

– Install clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20

– If present, install the crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

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

gr. 87 .

37

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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

Note

Install the clutch pedal with a new bearing axle.

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

⇒ “1.10 Removing and installing the bracket without the mas‐

ter cylinder (Rapid) ”, page 34 .

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

-direction of arrow-.

-1- = 8 mm Allan key.
The catches -A- are destroyed.
Then the pegs -B- are positioned horizontally to the fitting posi‐

tion.
– 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 axle.

– 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.

38

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

– Position the over-centre helper spring on the centering pin of

the clutch pedal -arrow-.

– 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.

Gearbox 02R - Edition 08.2014

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

-1- = 8 mm Allan key.

• The catches -B- must click audibly into place.
Then the pegs -A- are positioned vertically.
– Press the support -2- into the recess on the clutch pedal -3-

until it clicks audibly into place.

– Install bracket without master cylinder

⇒ “1.10 Removing and installing the bracket without the mas‐
ter cylinder (Rapid) ”, page 34

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

Note

♦

Install the clutch pedal with a new bearing axle.

♦

If only the tension spring is removed, pay attention

⇒ page 41 .

Special tools and workshop equipment required
♦ Hook - 3438­♦ Pliers - T10005­♦ Allan key, wrench size 8 mm, commercially available

39

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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

Rep. gr. 87 .

– If present, remove crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

– Remove clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20 .

– 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 axle for the clutch pedal.
– Turn the bearing axle for the clutch pedal to the left in

-direction of arrow-.

-1- = Allan key, wrench size 8 mm.
The catches -A- are destroyed.
Then the studs -B- are positioned horizontally.
– Subsequently move the clutch pedal so that the bearing axle

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

• Install the clutch pedal with a new bearing axle.

40

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

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

master cylinder.

– Insert a new bearing axle in the bracket and the clutch pedal.

– Position the studs -A- horizontally.
– Turn the bearing axle to the right in -direction of arrow-.

-1- = Allan key, wrench size 8 mm.

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

the master cylinder.

Gearbox 02R - Edition 08.2014

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

2nd spring coil -arrows-.

– Install clutch pedal switch - F36-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20

– If present, install the crash strut

⇒ “1.5.2 Removing and installing crash strut”, page 21 .

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

gr. 87 .

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

41

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

1 - Brake fluid reservoir
2 - Supply hose

❑ out of rubber
❑ on certain vehicles out

of plastic ⇒ page 44

❑ if the return hose is

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

❑ test tightness

⇒ “1.16 Check hydraulic
clutch control”,
page 47

3 - Master cylinder

❑ removing and installing

(Fabia II 2007 ►; Room‐
ster 2006 ►)

⇒ “1.17 Removing and
installing the master cyl‐
inder (Fabia II 2007 ►;
Roomster 2006 ►)”,
page 48

❑ removing and installing

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

⇒ “1.18 Removing and
installing the master cyl‐
inder (Fabia II 2011 ►;
Roomster 2011 ►; Rap‐
id 2011 ►; Rapid NH)”,
page 50

❑ after installing, bleed the

clutch control

⇒ “1.20 Bleeding the
clutch control ”,
page 54

❑ test tightness ⇒ “1.16 Check hydraulic clutch control”, page 47

4 - Clamp

❑ 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 43
❑ installing ⇒ page 44

6 - Clutch pedal

❑ removing and installing (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)

⇒ “1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 36

❑ Removing and installing clutch pedal with tension springs (Fabia II 2011 ►; Roomster 2011 ►)

⇒ “1.13 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011
►)”, page 39

❑ Removing and installing (Rapid)

⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”, page 38

7 - 25 Nm

❑ self-locking
❑ always replace ⇒ Electronic Catalogue of Original Parts

42

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

Gearbox 02R - Edition 08.2014

8 - 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 44
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ test tightness ⇒ “1.16 Check hydraulic clutch control”, page 47

9 - Tube-hose line

❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ test tightness ⇒ “1.16 Check hydraulic clutch control”, page 47

10 - Support

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

11 - Support

❑ for clipping in the tube-hose line -Pos. 9­❑ not fitted to all vehicles
❑ Assignment ⇒ Electronic Catalogue of Original Parts

12 - 20 Nm

❑ not fitted to all vehicles
❑ Assignment ⇒ Electronic Catalogue of Original Parts

13 - Vent valve

❑ Bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
14 - Dust cap
15 - Clamp

❑ to remove the tube-hose line Pos. 9 pull out of the slave cylinder up to the stop

❑ to remove the tube-hose line -Pos. 9- pull out of the slave cylinder -Pos. 17- up to the stop
16 - Gearbox
17 - Slave cylinder

❑ removing and installing ⇒ “1.19 Removing and installing the slave cylinder”, page 51

❑ after installing, bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54

Remove the support -A- from the actuating rod of the master cyl‐
inder in -direction of arrow-

43

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

Gearbox 02R - Edition 08.2014

Install the support -A- at the actuating rod of the master cylinder
in -direction of 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-, a gasket ring/O-ring must be inserted.

Vehicles with plastic return hose -1-:
♦ Gaskets -2- must be present on the return hose.
♦ Do not use hose clamp - MP7-602-

1.15 Summary of components - Hydraulic (Rapid)

44

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

Gearbox 02R - Edition 08.2014

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

❑ removing and installing

⇒ “1.18 Removing and
installing the master cyl‐
inder (Fabia II 2011 ►;
Roomster 2011 ►; Rap‐
id 2011 ►; Rapid NH)”,
page 50

❑ after installing, bleed the

clutch control

⇒ “1.20 Bleeding the
clutch control ”,
page 54

5 - Support

❑ only replace if the mas‐

ter cylinder Pos. 3 has

been removed
❑ removing ⇒ page 46
❑ installing ⇒ page 46

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 line
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

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 47
❑ 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

45

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

❑ 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

❑ Bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
20 - Screw 20 Nm
21 - Slave cylinder

❑ removing and installing ⇒ “1.19 Removing and installing the slave cylinder”, page 51

❑ after installing, bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
22 - Clamp

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

Remove the support -A- from the actuating rod of the master cyl‐
inder in -direction of arrow-

Install the support -A- at the actuating rod of the master cylinder
in -direction of arrow-

46

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

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-, a gasket ring/O-ring must be inserted.

1.16 Check hydraulic clutch control

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

• If necessary. bleed the clutch control

⇒ “1.20 Bleeding the clutch control ”, page 54 .

– First of all check the brake fluid level in the brake fluid reser‐

voir.

Gearbox 02R - Edition 08.2014

Note

♦

The clutch hydraulic is connected to one of the chambers

-arrow 2- of the brake fluid reservoir by the return hose

-arrow 1-.

♦

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

Then check the following components of the hydraulic clutch con‐
trol for external leaks:

♦ Return hose between brake fluid reservoir and master cylin‐

der.

♦ Master cylinder.
♦ Tube-hose line or plastic line between master and slave cyl‐

inder

♦ Connection points (plug and screw connections) also in a non-

visible area.

♦ Slave cylinder.

Note

♦

Symptoms of an external leak are, amongst others, traces of
brake fluid on or below the gearbox, as well as on the noise
insulation under the gearbox.

♦

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

– Subsequently depress the clutch pedal carefully, at the same

time hold the clutch pedal in 5 different positions for approx.
20 seconds over the entire distance the pedal has to travel.
While doing so, a second person must check if fluid is leaking
from the components of the hydraulic clutch control

⇒ page 47 . At the same time the first person must check if the

clutch pedal falls through on its own while being held.

47

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Remove the slave cylinder from the gearbox last, - do not open

the line system - and check the collar for brake fluid leak.

– To do so, take off the collar from the tappet -arrow-.

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

Special tools and workshop equipment required
♦ Pliers - T10005­♦ Polycarbamide grease - G 052 142 A2­Removing

Note

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

– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 23 .
– Lay a cloth under the master cylinder.
– Using an extraction bottle extract as much brake fluid as pos‐

sible from the brake fluid reservoir.

48

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

– 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.

♦

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

– 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.

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

Rep. gr. 70 .

– Remove crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

– Remove clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-, if provided.

Gearbox 02R - Edition 08.2014

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 as
follows:

– Pull clutch pedal slightly into the passenger compartment.
– Insert pliers - T10005- in the clutch pedal recesses.
– Press together both sides of the support inwards using the pli‐

ers - T10005- -arrows- and separate the clutch pedal from the
master cylinder.

– Removing the over-centre helper spring

⇒ “1.3 Removing and installing the over-centre helper spring
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

– Remove the bearing/over-centre helper spring from the brack‐

et.

49

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Unscrew the nuts -arrows 1- and remove the bracket

-arrow A- together with the master cylinder.

– Unscrew pedal stop

⇒ “1.1 Summary of components - foot controls (Fabia II 2007

►; Roomster 2006 ►)”, page 10 ,-Pos. 19-.

– Remove the master cylinder.
Install
Installation is performed in the reverse order, pay attention to the

following points:
– Insert the bearing for over-centre helper spring in the bracket.

– 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 clutch pedal switch - F36-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007

►; Roomster 2006 ►)”, page 10 -Pos. 7-.

– Install crash strut (if present)

⇒ “1.2 Removing and installing the crash strut for the clutch

pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .

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

gr. 70 .
– After installing the master cylinder bleed the clutch control

⇒ “1.20 Bleeding the clutch control ”, page 54 .

Tightening torques

Bracket/clutch pedal to front wall

Master cylinder to front wall

Clutch pedal to bracket

1)

Replace self-locking nut.

1)

1)

1)

⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;

Roomster 2006 ►)”, page 10 , -Position 6-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;

Roomster 2006 ►)”, page 10 , -Position 13-

⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;

Roomster 2006 ►)”, page 10 , -Position 20-

1.18 Removing and installing the master cyl‐

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

Special tools and workshop equipment required
♦ Pliers - T10005­♦ Polycarbamide grease - G 052 142 A2­Removing
Removing bearing bracket with the master cylinder (Fabia II 2011

►; Roomster 2011 ►; Rapid NH 2013 ►)

50

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

⇒ “1.7 Removing and installing the bracket with the master cylin‐
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27 .

Removing bearing bracket with the master cylinder (Rapid 2011
►)

⇒ “1.8 Removing and installing the bracket with the master cylin‐
der (Rapid) ”, page 30 .

– 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.

– 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.

Installing bearing bracket with the master cylinder (Fabia II 2011
►; Roomster 2011 ►; Rapid NH 2013 ►)

⇒ “1.7 Removing and installing the bracket with the master cylin‐
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27 ,

(Rapid)

⇒ “1.8 Removing and installing the bracket with the master cylin‐
der (Rapid) ”, page 30 .

Gearbox 02R - Edition 08.2014

1.19 Removing and installing the slave cylin‐

der

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

Note

♦

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

⇒ “1.16 Check hydraulic clutch control”, page 47 .

♦

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.

♦

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.

51

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Removing

Note

If the battery earth strap is disconnected and connected, carry out
certain 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 battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 23 .
– Remove lock washer -arrow 1- for shift cable from gearbox

shift lever -A-.
Vehicles Fabia II and Roomster up to 05.07 and 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 Rapid NH (plastic
relay lever)

– Pull off shift cable from the stud.
– Remove relay lever together with cable lock

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rap‐

id NH)”, page 77 .

Continued for all vehicles
– Remove the gearshift lever -A-, for this step unscrew nut

-arrow 4-.

52

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

– Disconnect the Bowden cable support from gearbox

-arrows-.
– Tie up shift cable and selector cable.
– Place a non-fluffing cloth under the slave cylinder.
– Pull retaining clip -2- for tube-hose line out of the slave cylinder

up to the stop.

– Then pull the tube-hose line -3- out of the slave cylinder and

close openings.

– Pull the tube-hose line -3- out of the bracket -4-, if present, on

the gearbox.

– Unscrew the screws -5- for the slave cylinder and remove the

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

following points:
– Grease tappet head with grease for plug serration of clutch

disc - G 000 100 - .

Note

Gearbox 02R - Edition 08.2014

♦

Replace damaged gasket rings.

♦

Assign all the components via the ⇒ Electronic Catalogue of

Original Parts .

– Screw the slave cylinder onto the gearbox with the screws

-5-.

– Insert the tube-hose line -3- into the slave cylinder up to the

stop.
– Press in retaining clip -2- up to the stop.
– Press the tube-hose line into the bracket -4-, if present, at the

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

⇒ “1.20 Bleeding the clutch control ”, page 54 .

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

er.
For vehicles Fabia II and Roomster and Rapid NH

⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster,
Rapid NH)”, page 79

For vehicles Rapid

⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page
84

– Setting the shift mechanism

⇒ “1.12 Setting the shift mechanism”, page 86

– Install air filter ⇒ Engine; Rep. gr. 23 .
– Install the battery tray and battery ⇒ Electrical System; Rep.

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

27 .

53

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Tightening torque

Component Tightening torque
Slave cylinder to gearbox Fabia II, Roomster, Rapid NH

⇒ “1.14 Summary of components - Hydraulic (Fabia

II ►; Roomster ►; Rapid NH) ”, page 41

-Position 12­Rapid

⇒ “1.15 Summary of components - Hydraulic (Rapid)

”, page 44 -Position 20-

bracket for tube-hose line Fabia II, Roomster, Rapid NH

⇒ “1.14 Summary of components - Hydraulic (Fabia

II ►; Roomster ►; Rapid NH) ”, page 41

-Position 12­Rapid

⇒ “1.15 Summary of components - Hydraulic (Rapid)

”, page 44 -Position 20-

Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”,

page 74

Gearbox shift lever to gearbox ⇒ “1.8 Summary of components - Control cables”,

page 74

1.20 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 .
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 23 .
– Connect brake filling and bleeding device , e. g. -VAS 5234- .
To bleed use bleeder hose .
– Connect the ventilation hose with the drip bottle of the brake

bleeding device.

54

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

– Insert the bleeder hose on the slave cylinder -arrow- and open

the vent valve.
– Activate system with a pressure of 0.2 MPa (2 bar).
–

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

air bubbles are visible.
– Close vent valve.
– Press clutch pedal forcefully from stop to stop between 10 and

15 times.
– Open vent valve.
– Activate system with a pressure of 0.2 MPa (2 bar).
–

Allow another approx. 100 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

⇒ “1.20 Bleeding the clutch control ”, page 54 .

– Separate brake filling and bleeding device , e.g. -VAS 5234- .
– Install air filter ⇒ Engine; Rep. gr. 23 .
– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .

Gearbox 02R - Edition 08.2014

55

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

2 Repairing the clutch release mecha‐

nism

Special tools and workshop equipment required
♦ Grease for plug serration of clutch disc - G 000 100­♦ Sealing grease - G 052 128 A1-

1 - Gearbox
2 - Ball stud, 25 Nm

❑ remove previous grease

from the contact surface
of the release lever

❑ grease with grease for

plug serration of clutch
disc - G 000 100-

3 - Gasket ring for drive shaft

❑ fitted in guide bushing

Pos. 4

❑ Renew.

⇒ “5 Repairing gearbox
housing and clutch
housing”, page 151 .

❑ Fill half the space be‐

tween the sealing lips
and dust lips with seal‐
ing grease - G 052 128
A1-

4 - Guide bushing

❑ with vulcanized O-ring
❑ if O-ring is damaged, re‐

place guide bushing to‐
gether with O-ring

⇒ “5 Repairing gearbox
housing and clutch
housing”, page 151

❑ for removal, remove

clutch release lever
Pos. 7

❑ grease in the area of the

clutch release lever with
grease for plug serration
of clutch disc ­G 000 100 -

5 - Retaining spring

❑ attach to clutch release lever
6 - 20 Nm
7 - Clutch release lever

❑ remove and install ⇒ page 57 together with clutch release bearing Pos. 8

❑ remove previous grease from the contact surface of the clutch release lever

❑ Grease contact point on the ball stud with grease for plug serration of clutch disc - G 000 100­8 - Release bearing

❑ Do not wash the bearing, just wipe clean

❑ replace noisy bearings

❑ removing and installing ⇒ page 57

56

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

Gearbox 02R - Edition 08.2014

❑ Grease contact point on the clutch release lever with grease for plug serration of clutch disc - G 000 100

-

9 - Slave cylinder

❑ removing and installing ⇒ “1.19 Removing and installing the slave cylinder”, page 51

❑ Grease tappet head with grease for plug serration of clutch disc - G 000 100­10 - 20 Nm
11 - Mounting bolt

❑ secures the clutch release lever when installing the gearbox ⇒ “2.5 Installing the gearbox”, page 120

❑ unscrew after the gearbox has been installed ⇒ “2.5 Installing the gearbox”, page 120

Note

If a mounting bolt is not provided,
use bolt M8 x 35.

Remove and install clutch release lever with release bearing
Removing
– Unhook spring -arrow 1- upwards.
– Remove clutch release lever -arrow 2- from ball stud.
Install
– First mount spring -arrow 1- on the clutch release lever.
– Press clutch release lever -arrow 2- onto the ball stud.

Removing and installing the release bearing
– Press the catch pegs -arrows- together on the rear side of the

clutch release lever and remove the release bearing -A- from
the clutch release lever.

– To install, press the release bearing -A- into the clutch release

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

2. Repairing the clutch release mechanism 57

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

Gearbox 02R - Edition 08.2014

3 Repairing clutch

Fault finding of power transmission - problems with the clutch and
clutch control

⇒ “3.1 Fault finding power transmission - problems with the clutch
and clutch control”, page 60

Special tools and workshop equipment required
♦ Counterholder - MP1-223 (3067)­♦ Centering mandrel - MP3-475A (3190A)­♦ Grease for plug serration of clutch disc - 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

⇒ “3.1 Fault finding power transmission - problems with the clutch and clutch control”, page 60 .

♦

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 .

♦

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.

♦

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

♦

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

♦

The thrust surface of the pressure plate and the clutch disc lining must fully rest against the flywheel before
the screws are installed. Only then may the fixing screws be inserted.

58

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

1 - Flywheel

❑ make sure the centering

pins are tight

❑ 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

❑ Installation position for

basic flywheel: The
spring cage points to‐
wards the pressure
plate

❑ Fitting position for two-

mass flywheel

⇒ page 60

❑ center ⇒ page 59
❑ slightly grease the ser‐

ration

3 - Pressure plate

❑ removing and installing

⇒ page 59

❑ Check the extremities of

the membrane springs

⇒ page 60

❑ Check feather joints and

riveted joints

⇒ page 60

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

❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ loosen or tighten gradually and crosswise

Gearbox 02R - Edition 08.2014

Center the clutch disc and remove and install the pressure plate
– Release and tighten screws gradually and crosswise.
– When removing and installing, use counterholder - MP1-223

(3067)- .

Note

♦

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

♦

Tighten the screws crosswise so as not to damage the cen‐
tering holes and the centering pins of the flywheel.

3. Repairing clutch 59

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Fitting position of clutch disc in connection with two-mass flywheel

• Legend “side of gearbox” -arrow- points to the gearbox.

Check the extremities of the membrane spring

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

Check feather joints and riveted joints
– Check the feather joints between pressure plate and cover for

cracks as well as the riveted joints for firm seating.

• Pressure plate with damaged feather joints or with loose rive‐
ted joints -arrows- must be replaced.

3.1 Fault finding power transmission - prob‐

lems with the clutch and clutch control

Note

Check hydraulic clutch control

⇒ “1.16 Check hydraulic clutch control”, page 47 .

Always check the fault mentioned by the customer first before
repairing the clutch. During this procedure, it must be determined
if indeed there is a fault of the clutch or if the cause is only an
incorrect setting of the shift mechanism.

Complaint Fault type 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 part, vent air

from the line system; top up with
brake fluid.

60

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

Gearbox 02R - Edition 08.2014

Complaint Fault type Measure

♦ Release bearing on the guide

bushing is tilted, seizured.

– Replace guide bushing and re‐

lease bearing.

♦ Membrane spring of the pres‐

– Replace pressure plate.

sure plate broken.

Complaint Fault type Measure
Actuating force on the clutch pedal

too high.

♦ Over-centre helper spring de‐

fective.

♦ Clutch release force increased

due to wear of clutch linings.

– Replace over-centre helper

spring.

– Inform customer (higher release

force with increased wear).

– Replace clutch disc, when the

distance base/rivet is below 0.1
mm.

♦ Release bearing on the guide

– Replace defective components.

bushing is tilted, seizured.

♦ Pressure plate with wrong

spring identification.

– Assign pressure plate via the ⇒

Electronic catalogue of original
parts .

♦ Mechanical fault of the pressure

– Replace defective components.

plate/clutch disc.

♦ Clutch disc on the serration

sluggish/jams.

– Check serration of the hub for

damage (burrs), if necessary re‐
place clutch disc.

– Clean the hub and the drive

shaft from corrosion and grease
with grease for plug serration of
clutch disc - G 000 100- . Move
clutch disc back and forth, re‐
move excess grease.

Complaint Fault type Measure
Noises when operating the clutch

pedal.

♦ Release bearing defective,

guide bushing is not O.K, con‐

– Always replace noisy release

bearings.

tact surface worked-in.

– Replace damaged guide bush‐

ing.

♦ The contact surface of the pres‐

– Replace pressure plate.
sure plate is defective (the tips
of the membrane spring are
kinked, bent). Release bearing

– Check release bearing, guide

bushing, replace if necessary.

is off-center.

– Check adjustment of clutch re‐

lease lever.

– Check dowel sleeves.

♦ Centre displacement of engine/

– Check dowel sleeves.
gearbox.

♦ Clutch disc incorrectly installed. – Correct installation.

3. Repairing clutch 61

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Complaint Fault type Measure

Complaint Fault type 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.

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

Electronic catalogue of original
parts .

♦ 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.

– Bleed system; check system,

top up with brake fluid.

– Replace defective component,

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

– Inform customer.

♦ Pressure plate uneven due to in‐

correct installation, clutch disc
warped due to improper han‐
dling.

♦ Tips of membrane spring broken

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

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

♦ Lining glued to the flywheel

(long immobilization time, high
humidity).

♦ Clutch disc on the serration

sluggish/jams. Corroded hub,
damaged during assembly. Hub
profile knocked out on one side.

– Check components, if necessa‐

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

– If afterwards scratching still oc‐

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

– Replace pressure plate.

– Check release bearing, guide

bushing, replace if necessary.

– Check dowel sleeves.

Electronic catalogue of original
parts .

– Slightly rub down friction surfa‐

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

– Check serration of the hub for

damage, if necessary replace
clutch disc.

– Remove corrosion and traces of

grease from hub and shaft.
Grease shaft with grease for
plug serration of clutch disc ­G 000 100 - .

62

♦ Lifting of pressure plate too low

(wrong pressure plate installed).

– 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.

– Assign pressure plate via the ⇒

Electronic catalogue of original
parts .

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

Gearbox 02R - Edition 08.2014

Complaint Fault type Measure

♦ 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 type Measure
Load change jolts when throttle is

depressed and sudden reduction of
the engine speed.

♦ Assembly bearing is too soft. – Inform customer. Assign hanger

via the ⇒ Electronic Catalogue

of Original Parts

♦ Irregular engine running. – Check engine setting, 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 type Measure
Clutch slips through, no or bad pre‐

drive.

♦ Wrong clutch disc, wrong pres‐

sure plate installed.

– Assign the clutch disc and pres‐

sure plate via the ⇒ Electronic

catalogue of original parts .

♦ Cutch disc is worn out, burnt,

– Replace clutch disc.
pressure plate overheated,
scoring, pressure plate warped

– Replace pressure plate.
through incorrect assembly,
contact pressure of the pressure

– Inform customer.
plate too low, driving error, nat‐
ural wear.

♦ Clutch disc, pressure plate, fly‐

– Replace clutch disc.
wheel oily. Shaft seal of the en‐
gine or the drive shaft defective.
Grease on the contact surface

– Clean contact surfaces of pres‐

sure plate and flywheel.
through excess greasing of the
hub.

– Replace shaft seal, remove ex‐

cess grease from the drive shaft.

♦ Clutch disc incorrectly installed. – Correct installation, check

clutch disc, replace if necessary.

♦ Flywheel depth too large or ex‐

cessive abrasion on the contact
surface of the lining.

– Assign the sealing flange via the

⇒ electronic catalogue of origi‐

nal parts .

– Inspect clutch disc, pressure

plate, replace if necessary.

♦ Slave cylinder leaking. – Replace slave cylinder.

3. Repairing clutch 63

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

Complaint Fault type Measure
Clutch grabbing,

unit shaking.

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

level, check system for tight‐
ness.

– Replace defective part.

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

♦ Driving error, speed too low

when starting.

♦ 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).

♦ The contact surface of the pres‐

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

♦ The housing of the pressure

plate was warped when instal‐
led. Contact surface of the pres‐
sure plate lifts off only unilater‐
ally.

– Inform customer.

Electronic catalogue of original
parts .

– Assign the assembly bracket via

the ⇒ Electronic catalogue of
original parts .

– Check shaft seal of drive shaft or

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.

– 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.

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

pling.

♦ Drive schaft too heavily greased

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

♦ Carrier earth/drive shaft is ac‐

celerated with sudden coupling.
The drive shaft serration of the
pinions in mesh knocks; for
clutch discs with predamper the
noise increases as the predam‐
per reaches the stop.

– 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.

– Inform customer.

64

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

Gearbox 02R - Edition 08.2014

Complaint Fault type Measure
Noises in idle. ♦ Torsional damper spring bro‐

– Replace clutch disc.

ken.

♦ Clutch disc without predamper

installed (idle rattling).

– Assign clutch disc via the ⇒

Electronic catalogue of original

parts .

♦ Pressure plate warped, broken,

– Replace pressure plate.

imbalance.

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

necessary.

♦ Displacement of engine/gear‐

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 65

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

34 – Controls, housing

1 Shift mechanism

⇒ “1.1 Fitting location of shift mechanism”, page 66
⇒ “1.2 Summary of components of the shift mechanism ”,

page 68
⇒ “1.3 Summary of components - gearshift knob and cover”, page

69
⇒ “1.4 Separating collar from gearshift lever (Fabia II, Roomster)

”, page 69
⇒ “1.5 Separating collar from gearshift lever (Rapid)”, page 70
⇒ “1.6 Remove and install gearshift knob and shift lever collar

(Rapid NH)”, page 72 .
⇒ “1.7 Summary of components - Shift lever and shift housing”,

page 72
⇒ “1.8 Summary of components - Control cables”, page 74
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid

NH)”, page 77
⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster,

Rapid NH)”, page 79
⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page

84
⇒ “1.12 Setting the shift mechanism”, page 86

1.1 Fitting location of shift mechanism

-Arrow A- Shift movement

-Arrow B- Selector movement

66 Rep. gr.34 - Controls, housing

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

❑ take off before removing

the shift mechanism
1 - Gearshift lever
2 - Reversing lever

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

Gearbox 02R - Edition 08.2014

1. Shift mechanism 67

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

1.2 Summary of components of the shift mechanism

Note

♦

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

♦

To replace the control cables, remove the shift mechanism (Fabia II, Roomster, Rapid NH)

⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH)”, page 79 , (Rapid)
⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page 84 .

♦

Do not kink the control cables.

I - Summary of components ­Gearshift knob and cover

⇒ “1.3 Summary of compo‐
nents - gearshift knob and cov‐
er”, page 69

II - Summary of components ­Shift lever and shift housing

⇒ “1.7 Summary of compo‐
nents - Shift lever and shift
housing”, page 72

III - Summary of components ­Control cables

⇒ “1.8 Summary of compo‐
nents - Control cables”,
page 74

Removing and installing shift
mechanism (Fabia II, Room‐
ster, Rapid NH)

⇒ “1.10 Remove and install
shift mechanism (Fabia II,
Roomster, Rapid NH)”,
page 79 , (Rapid)
⇒ “1.11 Removing and instal‐
ling shift mechanism (Rapid) ”,
page 84

Setting the shift mechanism

⇒ “1.12 Setting the shift mech‐
anism”, page 86

68 Rep. gr.34 - Controls, housing

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

Gearbox 02R - Edition 08.2014

1.3 Summary of components - gearshift knob and cover

1 - Gearshift knob

❑ with collar
❑ it can be different in

shape on individual

models

❑ The gearshift knob and

collar cannot be separa‐

ted

❑ always replace together

⇒ Electronic Catalogue

of Original Parts

❑ Removing and installing

(Fabia II, Roomster)

⇒ “1.4 Separating collar

from gearshift lever (Fa‐

bia II, Roomster) ”, page

69 , (Rapid)

⇒ “1.5 Separating collar

from gearshift lever

(Rapid)”, page 70 ,

(Rapid NH)

⇒ “1.6 Remove and in‐

stall gearshift knob and

shift lever collar (Rapid

NH)”, page 72

❑ Plaque of gearshift lever

can only be separated

from the gearshift knob

e.g. with a screwdriver.
2 - Centre console

1.4 Separating collar from gearshift lever

(Fabia II, Roomster)

Special tools and workshop equipment required
♦ Disassembly wedge - 3409-

1. Shift mechanism 69

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Lever off the collar with disassembly wedge - 3409- out of the

surround of 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 Separating collar from gearshift lever

(Rapid)

Special tools and workshop equipment required
♦ Release tool - T30098­– Lever off the collar frame with the disassembly wedge -

T30098- out of the surround for the centre console in

-direction of arrow-.

70 Rep. gr.34 - Controls, housing

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

– For this step, press on the frame in -direction of arrow- 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.

Gearbox 02R - Edition 08.2014

– 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 catches into the rear part of the centre

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

part.

1. Shift mechanism 71

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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.

– 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 lock up to the stop.

– Position the gearshift knob together with the collar and secure

it with the new open warm-type clamp -arrow- by pressing it

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

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

locks in the front area.

1.7 Summary of components - Shift lever and shift housing

Note

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

72 Rep. gr.34 - Controls, housing

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

Gearbox 02R - Edition 08.2014

1 - Lock washer

❑ removing and installing

⇒ page 74

2 - Spring
3 - Gasket

❑ between shift housing

and underbody

❑ self-adhesive
❑ stuck onto the shift

housing
4 - Shift lever
5 - Damping

❑ removing and installing

⇒ page 74

6 - Shift housing
7 - Insulating washer

❑ must be present in the

round slot -arrow- of the

shift lever Pos. 4
8 - Gasket

❑ replace ⇒ Electronic

Catalogue of Original

Parts
9 - Floor plate

❑ bend up tabs for remov‐

ing

❑ replace ⇒ Electronic

Catalogue of Original

Parts
10 - Bushing

❑ for selector cable

11 - Selector cable

❑ slacken from selector angle plate within the shift mechanism
❑ press onto selector angle plate within the shift mechanism
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86

12 - Shift cable

❑ slacken from the shift lever guide within the shift mechanism
❑ press onto the selector angle guide within the shift mechanism
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86

13 - 23 Nm

❑ 4 pieces

1. Shift mechanism 73

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

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-. While doing so remove circlip

-A-.

Note

♦

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

♦

Release spring carefully.

Removing and installing damping -arrow­– Press the pressure spring leg -A- to the left until it is located

next to the damping -arrow-.

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

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

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

1.8 Summary of components - Control cables

Note

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

74 Rep. gr.34 - Controls, housing

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

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

⇒ “1.1 Fitting location of

shift mechanism”,

page 66

❑ after installing set shift

mechanism

⇒ “1.12 Setting the shift

mechanism”, page 86

2 - Selector cable

❑ slacken from selector

angle plate within the

shift mechanism

❑ press onto selector an‐

gle plate within the shift

mechanism

❑ connect with cable lock

Pos. 10

❑ Fitting position

⇒ “1.1 Fitting location of

shift mechanism”,

page 66

❑ after installing set shift

mechanism

⇒ “1.12 Setting the shift

mechanism”, page 86

3 - Grommet

❑ for selector cable

4 - Lock washer

❑ do not damage cables when removing

❑ always replace ⇒ Electronic Catalogue of Original Parts
5 - Shift housing
6 - Cable support

❑ out of plastic or metal
7 - Grommet

❑ 3 pieces

❑ for mounting of cable support to gearbox
8 - Spacer

❑ 3 pieces

Gearbox 02R - Edition 08.2014

9 - 20 Nm

❑ 3 pieces

❑ for cable support to gearbox
10 - Cable lock

❑ for selector cable at relay lever

❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86

1. Shift mechanism 75

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

Gearbox 02R - Edition 08.2014

❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are

different ⇒ page 77

❑ can be installed in tandem with the plastic relay lever (Fabia II, Roomster, Rapid NH)

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)”, page 77

❑ remove from plastic relay lever (Fabia II, Roomster, Rapid NH)

⇒ “1.9.2 Remove and install cable lock for selector cable from plastic relay lever”, page 79

❑ press onto plastic relay lever (Fabia II, Roomster, Rapid NH)

⇒ “1.9.2 Remove and install cable lock for selector cable from plastic relay lever”, page 79

❑ Assignment ⇒ page 77

11 - Cable lock

❑ for shift cable at gearbox shift lever
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are

different ⇒ page 77

❑ Assignment ⇒ page 77

12 - Lock washer

❑ always replace ⇒ Electronic Catalogue of Original Parts
❑ is not required, if the relay lever is made of plastic

13 - Bushings

❑ is not required, if the relay lever is made of plastic

14 - Reversing lever

❑ Fitting position ⇒ page 77
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86
❑ The metal relay lever is located in the bushings pos. 13 and secured with a lock washer pos. 12
❑ as of 06.07 the relay lever is made of plastic (Fabia II, Roomster, Rapid NH)
❑ Remove and install plastic relay lever together with cable lock (Fabia II, Roomster, Rapid NH)

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)”, page 77

❑ if the relay lever is made of plastic, neither the bushings pos. 13 nor the lock washer pos. 12 are required

(Fabia II, Roomster, Rapid NH)

15 - Sliding shoe
16 - Gearshift lever

❑ with balancing weight
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 77
❑ Fitting position ⇒ page 77
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86

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

76 Rep. gr.34 - Controls, housing

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

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

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

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

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II,
Roomster, Rapid NH)”, page 77

Install gearshift 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.

10 mm

Gearbox 02R - Edition 08.2014

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

sliding rail of the gearbox shift lever

1.9 Plastic relay lever as of 06.07 (Fabia II,

Roomster, Rapid NH)

Special tools and workshop equipment required
♦ Grease - G 000 450 02-

1. Shift mechanism 77

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

Gearbox 02R - Edition 08.2014

1.9.1 Removing and installing plastic relay lever

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

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

-direction of arrow 2-.

• Before removing the plastic relay lever, the cable lock must be

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

• The gearbox shift lever is located in the neutral position.

The relay lever is secured with a catch -arrow 1- on the gearshift
cover

– Carefully press down the catch -arrow 1- up to the stop.
– Then move relay lever back and forward in its bearing (direc‐

tion of operation). To do so, carefully pull out the cable lock.

• Only remove cable lock on removed relay lever ⇒ page 79 .

Note

To install, grease bearing points and friction surfaces with grease

- G 000 450 02- .

– Press cable lock onto the relay lever ⇒ page 79 .
– Insert relay lever together with cable lock.

• The catch -arrow 1- secures the relay lever.

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

The relay lever is secured with a clip -arrow 1- on the gearshift
cover

– Remove the clip -arrow 1- from the opening in the relay lever.
– Afterwards, pull the relay lever together with the cable lock out

of its bearing point in the gearshift cover.

• Only remove cable lock on removed relay lever ⇒ page 79 .

Note

To install, grease bearing points and friction surfaces with grease

- G 000 450 02- .

– Press cable lock onto the relay lever ⇒ page 79 .
– Insert relay lever together with cable lock.
– Secure the relay lever with a clip -arrow 1-.

78 Rep. gr.34 - Controls, housing

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

1.9.2 Remove and install cable lock for selec‐
tor cable from plastic relay lever

Remove cable lock for selector cable from plastic relay lever

• Relay lever removed.

– Insert 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.

• It must be located behind the catch ⇒ page 78 .

Gearbox 02R - Edition 08.2014

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

Special tools and workshop equipment required
♦ 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 .
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .

1. Shift mechanism 79

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Remove circlip -3- for shift cable from gearbox shift lever -1-.
– Pull off shift cable from the stud -arrow-.
Metal relay lever (Fabia II and Roomster up to 05.07)
– Remove circlip -4- for selector cable from relay lever -2-.
– Remove selector cable and shift cable from the studs.
Plastic relay lever

Separate cable lock from selector cable

• Before removal, the cable lock must be separated from the
selector cable in order to avoid damage to the selector cable.

– 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-.

– Remove relay lever together with cable lock

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rap‐
id NH)”, page 77 .

Continued for all vehicles

– Disconnect the Bowden cable support from gearbox

-arrows-.

– Remove gearshift knob and shift lever collar.
♦ Fabia II and Roomster

⇒ “1.4 Separating collar from gearshift lever (Fabia II, Room‐
ster) ”, page 69 .

♦ Rapid NH

⇒ “1.6 Remove and install gearshift knob and shift lever collar
(Rapid NH)”, page 72 .

– 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.

80 Rep. gr.34 - Controls, housing

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

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

-arrows-.

– Remove tunnel bridge -arrows-.
Vehicles Fabia and Roomster
– Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 .
Vehicles Rapid NH
– Fit the stiff cover onto the decoupling element of the exhaust

system ⇒ Engine; Rep. gr. 26 .

– Separate the exhaust system at the clamping sleeve ⇒ En‐

gine; Rep. gr. 26 and secure the exhaust pipe so that it cannot
unhook freely.

– Push the pre-exhaust pipe out of the retaining straps and se‐

cure the exhaust pipe in such a way that it cannot unhook
freely.

– Remove bracket for retaining straps of rear silencer from the

body.

Gearbox 02R - Edition 08.2014

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

contact with the rear axle.

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

1. Shift mechanism 81

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

1.10.2 Install

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

The holes in the cable locks have different diameters

⇒ “1.8 Summary of components - Control cables”, page 74

– 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 removal ⇒

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 installed together

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rap‐
id NH)”, page 77 .

– 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 .

– If present, position the noise insulation on the shift housing.
– Install centre console ⇒ Body Work; Rep. gr. 68 .
– Setting the shift mechanism

⇒ “1.12 Setting the shift mechanism”, page 86 .

– Install air filter ⇒ Engine; Rep. gr. 23 .
– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .

Note

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

82 Rep. gr.34 - Controls, housing

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

Tightening torques

Components Tightening torque
Underbody cover 2 Nm

Shift housing to body ⇒ “1.7 Summary of components - Shift lever and shift housing”, page 72
Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”, page 74
Tunnel bridge ⇒ Engine; Rep. gr. 26
Unbolt bracket for exhaust pipe ⇒ Engine; Rep. gr. 26

Gearbox 02R - Edition 08.2014

83

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

1.11 Removing and installing shift mecha‐

nism (Rapid)

Special tools and workshop equipment required
♦ Release tool - T30098­♦ 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 .
– Remove lock washer -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 selector cable from the stud -arrow-.

– Remove Bowden cable support -arrows-.
– Remove gearshift knob and shift lever collar

⇒ “1.5 Separating collar from gearshift lever (Rapid)”,
page 70 .

– Remove the centre console ⇒ Body Work; Rep. gr. 68 .
– If present, remove noise insulation from shift housing.

– Unscrew nuts -arrows- attaching the shift housing.

84

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

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

-arrows-.

– Remove tunnel bridge -arrows-.
– Fit the stiff cover onto the decoupling element of the exhaust

system ⇒ Engine; Rep. gr. 26 .

– Separate the exhaust system at the clamping sleeve ⇒ En‐

gine; Rep. gr. 26 and secure the exhaust pipe so that it cannot
unhook freely.

– Push the pre-exhaust pipe out of the retaining straps and se‐

cure the exhaust pipe in such a way that it cannot unhook
freely.

– Unhook rear silencer in such a way that it does not come in

contact with the rear axle.

– Remove bracket for retaining straps of rear silencer from the

body.

Gearbox 02R - Edition 08.2014

– 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:

85

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

The holes in the cable locks have different diameters

⇒ “1.8 Summary of components - Control cables”, page 74

– 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 removal ⇒

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

⇒ “1.12 Setting the shift mechanism”, page 86

– Install air filter ⇒ Engine; Rep. gr. 23 .
– 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 torque

Components Tightening torque
Underbody cover 2 Nm

Shift housing to body ⇒ “1.7 Summary of components - Shift lever and shift housing”,

page 72

Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”, page 74
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.

86

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

• Shift mechanism operates freely.

• Operating and transmission elements of the shift mechanism
are in perfect condition.

• Gearbox in Neutral.

Note

After the battery earth strap is disconnected and re-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 .
– Pull forward the locking mechanism at shift cable and at se‐

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

Gearbox 02R - Edition 08.2014

Fix the gearshift shaft as follows:
– Press down the gearshift shaft in -direction of arrow 1-.
– When pressing down the gearshift shaft turn angle lever -A- in

-direction of arrow 2- upwards and at the same time press it in
carefully until it locks into the gearshift shaft.

– Remove shift lever collar:
♦ Fabia II, Roomster

⇒ “1.4 Separating collar from gearshift lever (Fabia II, Room‐
ster) ”, page 69

♦ Rapid

⇒ “1.5 Separating collar from gearshift lever (Rapid)”,
page 70

♦ Rapid NH

⇒ “1.6 Remove and install gearshift knob and shift lever collar
(Rapid NH)”, page 72

– Pull the collar upwards over the gearshift knob.
– Guide shift lever in Neutral position to the left into the 1st/2nd

gear gate via the leg.

87

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Insert rig pin - T10027A- into the hole -A- and into the hole

-B-.

– Turn locking mechanism at shift cable and at selector cable to

the right up to the stop -direction of arrow-.

The spring pushes the locking mechanism into the initial position.

– Turn angle lever -A- back to the initial position

-in direction of arrow-.

Note

The angle lever -A- must be pressed out of the gearbox housing
and must point vertically upwards.

– Pull rig pin - T10027A- out of hole -A- and -B-.
– Perform a functional test of the shift mechanism

⇒ “1.12.1 Operation”, page 88 .

– Fit collar into the surround for centre console.
– Install air filter ⇒ Engine; Rep. gr. 23 .
– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .

1.12.1 Operation

• Shift lever must be positioned in Neutral position in the selector

lever gate of the 3rd/4th gear.
– Actuate clutch pedal.
– Shift through all gears several times. Pay particular attention

to proper operation of the reverse gear lock.

88

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

If a gear catches when engaged again. set the shift mechanism
once again ⇒ “1.12 Setting the shift mechanism”, page 86 .

Gearbox 02R - Edition 08.2014

89

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

2 Removing and installing the gearbox

⇒ “2.1 Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►)”,
page 90

⇒ “2.2 Removing gearbox (Fabia II 2011 ►; Roomster 2011 ►)”,
page 97

⇒ “2.3 Removing gearbox (Rapid) ”, page 106
⇒ “2.4 Removing gearbox (Rapid NH)”, page 113
⇒ “2.5 Installing the gearbox”, page 120
⇒ “2.5.1 Tightening torques (Fabia II, Roomster) ”, page 122
⇒ “2.5.2 Tightening torques (Rapid) ”, page 124
⇒ “2.6 Tightening torques (Rapid NH)”, page 125
⇒ “2.7 Transporting the gearbox”, page 126

2.1 Removing gearbox (Fabia II 2007 ►;

Roomster 2006 ►)

Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­♦ Adapter - MP9-200/3 (10-222A/3)­♦ Gearbox mount - 3282­♦ Adjusting plate - T30020­♦ Engine and gearbox jack e.g. -V.A.G 1383 A­♦ Grease for plug serration of clutch disc - G 000 100-

Note

♦

All cable straps which are detached or cut open when remov‐

ing, should be fitted on again in the same place when installing.

♦

After the battery earth strap is disconnected and re-connected,

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

27 .

– Disconnect the earth strap from the battery with the ignition

off.
– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove air filter housing complete with air guide hose ⇒ En‐

gine; Rep. gr. 23 .
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .

90

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

– Remove lock washer -arrow 1- for shift cable from gearbox

shift lever -A-.
– Pull off shift cable from the stud.
Metal relay lever (up to 05.07)
– Remove circlip -arrow 2- for selector cable from relay lever

-B-.
– Pull selector cable off the stud.
– Detach circlip -arrow 3- from the relay lever -B- and remove

relay lever.

Note

Always replace circlips ⇒ Electronic Catalogue of Original Parts

Plastic relay lever

• Before removal, the cable lock must be separated from the

selector cable in order to avoid damage to the selector cable.

– 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-.
– Remove relay lever together with cable lock

⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rap‐
id NH)”, page 77 .

Continued for all vehicles:

Gearbox 02R - Edition 08.2014

– Remove the gearshift lever -A-, for this step unscrew nut

-arrow 4-.

2. Removing and installing the gearbox 91

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Remove cable support from the gearbox -arrows- and tie up

laterally together with selector cable and shift cable

– Remove bracket -B- from the gearbox and pull off from the

tube-hose line -A-.

– Remove the slave cylinder -arrows- and lay aside, secure with

wire, do not open the line system.

Caution

Do not depress the clutch pedal.

For vehicles with particle filter
– Remove charge-air pipe from exhaust turbocharger to charge

air cooler ⇒ Engine; Rep. gr. 21 .

Continued for all vehicles

– Disconnect plug -arrow 1- from reversing light switch - F4- .
– Remove connector -arrow 2- and cable -arrow 3- from the

starter.
– Expose cables.
– Remove engine/gearbox connecting screws at the top.
– Remove top securing screws at starter.

– Unplug connector -arrow- from speedometer sender - G22- (if

available).

92

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

– Remove bracket for engine cover -arrow- (install in this hole

one of the 2 spindles of the supporting device).

– If hose and cable connections are located in the area of the

lifting eye of the engine for the supporting device - MP9-200
(10-222A)- , these must now be removed.

– Install supporting device - MP9-200 (10-222A)- .
– Take up the weight of the engine/gearbox unit at the spindles.
– Remove front left wheel ⇒ Chassis; Rep. gr. 44 and raise

vehicle.

– Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 .

Gearbox 02R - Edition 08.2014

– If present, remove heat shield for drive shaft from the engine

-arrows-.

– Unscrew bracket from starter -arrow- and lay aside together

with lines.
– Removing starter ⇒ Electrical System; Rep. gr. 27 .
– Remove the front left wheelhouse liner ⇒ Body Work; Rep.

gr. 66 .
– Turn the sterring wheel up to the stop to the left and remove

drive shafts from the flange shafts ⇒ Chassis; Rep. gr. 40 .
– Tie up right drive shaft as far as possible, e.g. with cord. Avoid

damaging the paintwork on the drive shaft during this opera‐

tion.
For vehicles without particle filter
– Remove pre-exhaust pipe with catalytic converter ⇒ Engine;

Rep. gr. 26 .
Continued for all vehicles

2. Removing and installing the gearbox 93

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Mark installation position of bolts -1- from left steering joint.
– Unscrew screws -1- for left steering joint ⇒ Chassis; Rep. gr.

40 .

– Unbolt coupling rod -2- from the anti-roll bar -arrow- ⇒ Chas‐

sis; Rep. gr. 40 .
– Turn coupling rod upwards.
– Swivel out left wheel-bearing housing.
– Swivel the drive shaft into the wheelhouse and secure it to the

suspension strut, e.g. with cord. Avoid damaging the paint‐

work on the drive shaft during this operation.

– Screw out screws -arrows- and take out fan shroud down‐

wards. While doing so, disconnect the plug connection.

Note

On vehicles with air conditioning system, additionally unscrew the
fixing screws (in the upper area of the fan shroud) of the bracket
for refrigerant line.

– Remove pendulum support -arrows 1- and -arrow 2-.

Note

When installing the pendulum support position the screws

-arrows 1- in the elongated holes in such a way that there is max‐
imum distance between the gearbox and the assembly carrier.

– Unscrew the engine/gearbox connecting screw below the right

flange shaft.

– Remove small cover plate -A- (if present) for flywheel behind

the right flange shaft -arrows-.
For vehicles with particle filter

94

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

– Remove the holding bracket for the exhaust pipe -1-.
– Separate the exhaust system behind the pre-exhaust pipe at

the clamping sleeve and secure with wire to the body ⇒ En‐
gine; Rep. gr. 26 .

– Release the assembly carrier (center) ⇒ Chassis; Rep. gr.

40 .

Continued for all vehicles

– Release screws -arrows- for engine mounting from engine

holder.

Gearbox 02R - Edition 08.2014

Note

Do not slacken the fixing nut for the engine mount.

– Unscrew the fixing screws -arrows- from the gearbox mount.

2. Removing and installing the gearbox 95

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014

– Lower engine/gearbox unit sufficiently at the two spindles until

the fixing screws attaching the gearbox mounting bracket -A-

are accessible from the left wheelhouse.

Note

When lowering the engine/gearbox unit, make sure the gearbox
does not touch the assembly carrier.

Unscrew the fixing screws -arrows- of the gearbox console and
remove the gearbox console -A- from the gearbox.

– Insert gearbox mount - 3282 - into engine/gearbox jack , e.g.

-V.A.G 1383 A- .

Complete engine and gearbox jack with gearbox mount - 3282- ,
adjusting plate - T30020- for gearbox “02R” and support elements
as follows:

– Position adjusting plate - T30020 - onto the gearbox mount -

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

adjusting plate .

– Screw in the mounting elements -A- and -C- as shown on ad‐

justing plate .
– Screw in the bolt - 3282/29- , as indicated on the adjusting

plate.

– Position the engine and gearbox jack below the vehicle, the

arrow -symbol B- (in the previous figure) on the adjusting plate

points in the direction of travel/vehicle.
– Align adjusting plate parallel to the gearbox and lock securing

mounts at gearbox.
– Remove the bottom engine/gearbox connecting screws.
– Press gearbox off the engine and swivel towards the assembly

carrier.
– Via the spindles swivel the gearbox backwards and down to‐

wards the assembly carrier.
– Carefully lower the gearbox.
– Change the gearbox position at the spindles of the gearbox

mount - 3282- when lowering.

96