SKODA Self Study Program 18 – uses modern all-synchromesh gearboxes in the OCTAVIA for converting engine torque and speed SSP-18-Octavia-manual-gearbox-02K-02J

... gears provide
traction!

SKODA uses modern all-synchromesh gearboxes in the OCTAVIA for
converting engine torque and speed.

2

SP18-37

4

6

8

10

13

14

16

18

20

22

24

Contents

General 4

5-Speed Manual Gearbox 02K
5-Speed Manual Gearbox 02J

Manual Gearbox 02K 6

Diagram of Gearbox
Gearbox Housing
Manual Gearbox
Shift Mechanism in Gearbox
External Shift Mechanism
Clutch Mechanism

5

15

Manual Gearbox 02J 16

Diagram of Gearbox
Gearbox Housing
Manual Gearbox
Shift Mechanism in Gearbox
External Shift Mechanism
Clutch Mechanism

Lock Synchromesh 27

Differential 29
Drive Shafts 30

You can find notes on inspection and mainte­nance, setting and repair instructions in the
Workshop Manual.

Service Service Service Service

Service

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26

Service

3

General

The SKODA OCTAVIA features the manual gearboxes 02K and 02J for the transverse-mounted
engines.
Both manual gearboxes are based on proven Group components and have been matched to the
specific engine characteristics and the pendulum mounting in the OCTAVIA.

5-speed manual gearbox 02K

Manual gearbox and final drive form a single unit.
The code letters indicate the assignment of the gearbox to the corresponding engine. The code let-

ters are affixed together with the construction data of the gearbox on the gearbox housing.

Engine
Engine code letters
Gearbox code letters

1.6 l/55 kW 1.6 l/74 kW 1.9 l/50 kW
AEE AEH AGP
CZE DLP CZB

The manually-operated 5-speed manual gearboxes 02K and 02J have
been specifically developed for engines with a displacement of 1.6
litres up to 2 litres.
The clutch unit, the manual gearbox and the differential together with
the final drive are combined to form a compact gearbox block.
The gearbox has a high efficiency. Gearshifts are achieved with short,
convenient and precise travel.

4

SP18-5

5-speed manual gearbox 02J

Manual gearbox and final drive form a single unit.
The manual gearbox is assigned to the following engines:

Engine
Engine code letters
Gearbox code letters

1.8 l/92 kW 1.9 l/66 kW
AGN AGR
CZM DQY

SP18-29

5

Manual Gearbox 02K

Diagram of Gearbox

Clutch housing

Cover for gearbox housing

– Two-section housing (clutch housing, gearbox housing)

with compact cover for gearbox housing
– All shafts arranged parallel
– Helical gearing is used generally for the splines of the

selector gears and gearwheels of the forward speeds
– The shift forks are guided on a rod (single-rod shift)
– The speedometer is driven by the output shaft
– The selector gears (sliding gears) are mounted on needle

bearings

Gearbox housing

SP18-21

6

Manually operated
5-speed gearbox

Gearbox code letters

Gear reduction i =

CZE DLP CZB

z

2

z

1

Teeth of driven gear z
Teeth of driving gear z

iz

2

z

1

2

1

iz

2

z

1

i

Final drive 67 15 4.467 68 16 4.250 68 16 4.250
1st speed 38 11 3.455 38 11 3.455 38 11 3.455
2nd speed 35 18 1.944 35 18 1.944 35 18 1.944
3rd speed 36 28 1.286 37 27 1.370 36 28 1.286
4th speed 31 33 0.939 32 31 1.032 30 33 0.909
5th speed 38 51 0.745 34 40 0.850 37 52 0.712
Reverse 20

38

12203.167 20
38

12
20

3.167 20
38

12203.167

Speedometer 15 7 2.143 15 7 2.143 15 7 2.143
Capacity 1.9 l
Specification G 50 SAE 75-W 90

(synthetic oil)

Note:
In line with the service intervals for the SKODA OCTAVIA, the level of
the gear oil should be inspected every 30,000 km and topped up, if nec­essary.

Manual gearbox 02K has two shafts and five pairs of gears with helical gearing.
When the forward gears are shifted, a compulsory synchromesh is activated which
ensures quiet and convenient gear changes.
The advantage of the helical gearing is that the teeth are able to cope with higher
stresses (more than one tooth is constantly meshed) and the quieter operation of the
gearbox. Reverse gear is equipped with spur gearing with a compression spring. This
compression spring ensures that reverse gear can be easily engaged.
The shift forks are guided on a floating rod.
The rod is located between gearbox housing and clutch housing.
The gear steps have been selected so as to ensure optimum transmission of engine
power.
Fifth gear is designed to ensure low fuel consumption when driving at a continuous
speed.

7

Manual Gearbox 02K

Gearbox Housing

The axle bearing for the clutch mechanism is located directly in the cover for the gearbox housing.
It can be replaced with the gearbox installed.

A mechanical stop is cast onto the cover for the gearbox housing in order to limit the travel of the
clutch release lever, when the clutch slave cylinder is removed.

The mounting points for the pendulum support are located on the gearbox housing.
A coated end cover seals the assembly opening at the gearbox.

It should always be replaced after carrying out work on the gearbox.

End cover

Cover for gearbox housing

8

Note:
A comprehensive range of special tools is available for all the work involving remov­ing and inserting bearings, bushes, seals etc. Please refer to the Workshop Manual.

Gearbox housing

SP18-3

Clutch housing

9

Manual Gearbox 02K

Manual Gearbox

The input shaft runs in a grooved ball bearing in the gearbox housing.
This grooved ball bearing is secured by means of a retaining plate in the gearbox housing.
The input shaft in the clutch housing runs in a needle bearing.
The selector gears for 3rd, 4th and 5th speed are arranged on the input shaft.
The output shaft runs in two taper roller bearings and one needle bearing.
The selector gears of 1st and 2nd speed are arranged on the output shaft.
The differential is mounted at both sides in taper roller bearings.

Input shaft

Output shaft

10

Differential

SP18-18

Engaging reverse gear

The gearwheels of the reverse gear feature spur
gearing.
The higher noise level as a result of this is considered
acceptable.
No synchromesh is provided as reverse gear is only
engaged when the car is stationary.

5

3

1

The sliding sleeve of 1st and 2nd gear is at the same
time the reverse gear on the output shaft.
The change in the direction of rotation is achieved by
directly engaging the reverse idler gear between input
and output shafts.

Input shaft

Reverse idler
gear

R

4

2

SP18-35

1st/2nd speed sliding sleeve on
output shaft

SP18-32

11

Manual Gearbox 02K

Braking the selector gears when engaging reverse gear

The cause of "grating noises" when engaging the
non-synchromesh reverse gear is frequently the
long runout time of the input shaft until it stops.

For this reason, the input shaft - and thus also the
gear to be engaged - is braked when selecting
reverse gear.

Lock

Braking disc

Selecting

Shifting

5th gear synchromesh

5th gear shift
bridge

Input shaft

Reverse idler gear

SP18-31

When reverse gear is selected, the shift shaft carries out a movement in which a spring­tensioned braking disc is pressed against the lock of the shift shaft.

The spring-tensioned braking disc tilts and slightly displaces the 5th gear shift bridge.
As a result of this, 5th gear is synchronized and the input shaft is braked.
This is cancelled again when reverse gear is engaged.
The braking disc moves back into the initial position.
Reverse gear is engaged silently.

12

Shift Mechanism in the Gearbox

Shift shaft

Shift forks

5

3

1

The shift shaft runs in the gearbox housing in
a ball sleeve.
The reversing light switch is integrated in a
retaining bolt.
This bolt holds the bridge of the shift lock and
at the same time locks the shift shaft.
A spring always pushes the shift shaft and the
shift lever into the gate of 3rd/4th gear.

SP18-24

Retaining bolt

R

Ball sleeve

4

2

SP18-34

Shift shaft

To select the gear, the shift shaft, together
with the shift bridge and the shift finger, move
in an axial direction.
When the gear is engaged, the shift shaft
rotates together with the shift bridge and the
shift finger.

When reverse gear is engaged, the switch for
the reversing lights is operated.

Shift finger

SP18-36

Shift bridge

Shift forks

13

Manual Gearbox 02K

External Shift Mechanism

The gearshift lever is located in a shift housing which is attached to the floor tunnel
in the interior of the car.
The shift movements (selecting and engaging) are transmitted to the gearbox by a
shift rod.
Coupling rods are used to ensure that the relative movements between gearbox
and body are not transmitted to the gearshift lever.
The shift movements (selecting and engaging) of the gearshift lever are relayed to
the internal gearshift mechanism by shift rod, selector lever, coupling rods and
external shift lever.

Selector lever

Front shift rod

External shift lever

Shift rod with balancing
weight

Coupling rod

Gearshift lever

Shift housing

Relay lever

Note:
It is essential that the shift mechanism is precision-set in or­der to ensure smooth gearshifts.
A gauge at the shift housing is used for this purpose.
Further information is contained in the OCTAVIA Workshop
Manual - 5-Speed Manual Gearbox 02K.

Shift rod

SP18-1

14

Clutch Mechanism

The clutch is operated hydraulically. The slave cylinder presses on the
clutch lever which is attached to the end of the gearbox.
The clutch pushrod moves longitudinally through the input shaft.
The release movement is transmitted to the clutch by the clutch lever, the
release bearing and the clutch pushrod.

Note:
The clutch is mounted on the other way round.
The pressure plate is bolted to the crankshaft.
The flywheel points toward the gearbox.

Clutch lever

Release bearing

Flywheel

Pressure plate

Crankshaft

Clutch pushrod

SP18-22

15

Manual Gearbox 02J

Diagram of Gearbox

Gearbox housing

– Two-section housing with cover (clutch housing, gearbox housing)
– All shafts arranged in parallel
– Helical gearing is used for the splines of the selector gears and gearw-

heels of all forward speeds
– The selector gears (loose gears) run in needle bearings
– The selector gears of 1st to 4th speed are mounted on the output shafts
– The selector gear for 5th speed is mounted on the input shaft

Clutch housing

SP18-4

16

Manually operated 5-speed
gearbox

Gearbox code letters

Gear reduction i =

CZM DQY

z

2

z

1

Teeth of driven gear z
Teeth of driving gear z

iz

2

1

2

z

1

i

Final drive 72 17 4.235 61 18 3.389
1st speed 33 10 3.300 34 09 3.778
2nd speed 35 18 1.944 36 17 2.118
3rd speed 34 26 1.308 34 25 1.360
4th speed 35 34 1.029 34 35 0.971
5th speed 36 43 0.837 34 40 0.850
Reverse 17

36

10
20

3.060 18
36

09
20

3.600

Speedometer 13 22 0.591 13 22 0.591
Capacity 2 l
Specification G 50 SAE 75-W 90

(synthetic oil)

Note:
In line with the service intervals for the SKODA OCTAVIA, the level
of the gear oil should be inspected every 30,000 km and topped up,
if necessary.

Manual gearbox 02J is fitted to the SKODA OCTAVIA and is capable of transmitting
torques of more than 180 Nm.
The shift mechanism of the individual gears is transmitted through cables.
The clutch is operated hydraulically.
The gears are engaged by means of shift rockers.

17

Manual Gearbox 02J

Gearbox Housing

The housing of the 02J gearbox consists of two parts and a cover.
It is split transversely.

The gearbox housing also contains the attachment points for the pendulum
bearing support.

The separate shift cover which houses the shift shaft for the internal shift
mechanism, is mounted on the gearbox housing.

Shift cover

Cover for gearbox housing

SP18-38

Gearbox housing

18

Note:
A comprehensive range of special tools is available for all the work involving remov­ing and inserting bearings, bushes, seals etc. Please refer to the Workshop Manual.

Clutch housing

SP18-28

19

Manual Gearbox 02J

Manual Gearbox

The manual gearbox consists of three parallel shafts - input shaft, output shaft and
reverse idler shaft.
Input shaft and output shaft as well as the differential run in taper roller bearings.
2nd gear is a double-synchromesh design (see page 28).
The helically toothed gearwheels and selector gears are constantly meshed and
are engaged by synchronizing couplings.
The selector gear of 5th speed is located on the input shaft.
The selector gears of 1st to 4th speed are located on the output shaft.

Input shaft

Output shaft

Differential

SP18-13

20

Reverse idler shaft

Reverse gear not engaged

Reverse idler
gear

1st speed input
gear

SP18-11

The reverse idler shaft is located
between gearbox housing and clutch
housing.
It runs in needle bearings in order to
absorb the flywheel load transmitted by
the shift fork.

A helically-toothed gear which is con­stantly meshed with the input gear of
1st speed, is located on this shaft.

Reverse gear and 5th gear are
engaged by means of an independent
linkage.

Reverse selector gear

1st/2nd speed sli­ding sleeve

Reverse gear engaged

Reverse gear is engaged by moving the
reverse selector gear into the 1st and 2nd
speed sliding sleeve.
This features spur gearing on the outside.

The reverse selector gear likewise fea­tures spur gearing and is not synchro­nized.
The movement is supported by an over­centre spring.

The shift movement is initiated by the sep­arate shift fork for reverse gear.

SP18-12

21

Manual Gearbox 02J

Shift Mechanism in Gearbox

Rocker shift mechanism

Engaging of 1st to 5th gears is designed as a rocker shift mechanism.
The shift rockers for 1st to 4th gears are mounted in ball bearings which contrib­ute to the smooth operation of the shift mechanism.
The shift rocker for 5th gear is adjustable and has to be set separately.

Ball bearings

5th speed setting

Shift rockers

SP18-10

22

Internal shift mechanism

The shift shaft is located in the shift mechanism
which is linked to the shift rockers.

Lock

Selector movement

The shift shaft is moved in an axial direction dur­ing a selector movement.
It is prevented from rotating by the spring-ten­sioned locking ball.

When a gear is engaged, the shift shaft is rotated
to the connected shift finger.

Shift shaft

Shift finger

Shift movement

SP18-8

Shift finger

Neutral position

Shift position

The gear selected is engaged by means of the
shift mechanism/rocker.

Shift mechanism connected to
shift rocker

SP18-9

23

Manual Gearbox 02J

External Shift Mechanism

The shift movement (selecting and engaging) is
transmitted by two cables.
This offers the following benefits:

SP18-39

Shift cable

– Influences on gearshift operations are mini-

mized

– Improved protection against the transmission

of structure-borne sound
– A system requiring practically no maintenance
– Internal shift mechanism is located above the

oil fill level which reduces the forces acting on

the external shift mechanism

5

3

1

4

R

2

Once the gearshift lever is moved in the
Neutral position to select a gear, the
pivot point is located in the selector
housing.
The shift lever guide is linked in this
case to the selector housing.
The selector housing is mounted in the
shift housing.

A ball head positioned at the base end
of the selector housing carries out a
contrary movement.
The ball head is surrounded by the
selector angle bracket.
This converts the movement of the
gearshift lever when selecting a gear
into a pull/push movement.

Selector cable

Shift housing

Shift lever
guide

Shift pivot point

SP18-2

Selector housing

Select pivot point

SP18-16

24

Selector angle
bracket

The selector cable transmits the movement to a
relay lever on the shift cover.
The relay lever is linked to the shift shaft and lifts
the shift shaft up or presses it down, respectively.

Relay lever

SP18-15

Gearbox shift lever

If the shift lever is moved (shifted) in the direction
of the gear, the pivot point is located in the shift
lever guide.

The shift cable engages in the base of the shift
lever. The shift cable transmits the forward/back­ward movement to the gearbox shift lever.
The gearbox shift lever rotates the shift shaft in
the direction of the corresponding gear.

The shift finger which is connected to the shift
shaft, engages the gear.

Shift shaft with shift
finger

SP18-17

25

Manual Gearbox 02J

Clutch Mechanism

The clutch is operated hydraulically.
The slave cylinder is located at the gearbox housing.
It presses on the clutch release lever through a plunger.

The release bearing is located on a guide sleeve.
The clutch is operated through the release bearing.
After carrying out removal and installation work on the clutch mechanism, the clutch
system should be bled with a brake filling and bleeding appliance.

Slave cylinder

Clutch release lever

Plunger

Clutch

Guide sleeve

Release bearing

26

SP18-25

Note:
Before removing the gearbox, secure the clutch release
lever to prevent it slipping out.
Press the clutch release lever toward the housing for this
step and secure with an assembly bolt.

Lock Synchromesh

The gears of both manual gearboxes feature
helical gearing and are constantly meshed.
Each selector gear in addition features a cone
and a shift gearing through which the gear is
shifted by means of sliding sleeves.
The sliding sleeve is connected through the
synchronizer body to the gearbox shaft.

12 34 563

Design of the lock synchromesh in detail

The selector gears are pivot-mounted
and constantly meshed with the fixed
gearwheels.
The force flow is produced through the
sliding sleeves which can move axially.
The synchronizing of the selector gears
which is required for shifting a gear, is
produced by synchronizer rings.

1 - Selector gear
2 - Synchronizer ring
3 - Spring
4 - Locking element
5 - Synchronizer body
6 - Sliding sleeve

SP18-30

Locking element

Lock synchromesh installed

Sliding sleeve

Synchronizer body

SP18-19

The synchronizer body is firmly attached
on the shaft.
The synchronizer body contains
recesses for mounting the locking ele­ments which are pushed out by two
springs.
In the Neutral position the sliding sleeve
is held in the middle position by the
spring pressure.

The synchronizer ring likewise features
a friction cone, but is limited in its torsion
angle by mechanical stops.

27

Lock Synchromesh

Sliding sleeve with spur gearing for
reverse

Synchronizer body

2nd speed
selector gear

Shift gearing

Synchronizer rings

Locking element

1st speed
selector gear

When the shift force is transmitted
through the shift mechanism, the slid­ing sleeve is moved out of its middle
position. This movement is continued
at the synchronizer ring.
The friction cone of the synchronizer
ring is pushed against the cone of the
selector gear.
This is braked when shifting into a
higher gear - and accelerated when
shifting into a lower gear.
The further movement of the sliding
sleeve is blocked until the speeds
between synchronizer body and selec­tor gear are approximately matched.
Once synchromesh has been estab­lished between the selector gear and
the shaft, the sliding sleeve is able to
mesh with the splines of the selector
gear and the power transmission is
established.

SP18-23

Synchronizer rings

2nd gear double
synchromesh

As the power output of engines
increases, the synchromesh mecha­nism has to absorb greater forces.
That is why a double synchromesh
mechanism has been used.
Doubling the conical friction surfaces
boosts the power-handling capacity by
50 % and halves the gearshift force.

A double synchromesh is used on
gearbox 02J for synchronizing 2nd
gear.

SP18-33

Intermediate ring

28

Differential

Manual gearbox and differential together with final drive of both gearboxes form a sin­gle unit.

The differential is linked to the flange shafts through differential bevel gears.
These flange shafts are resiliently mounted by compression springs and tapered rings.
The tapered rings transmit the spring force to the housing of the differential and preten­sion the flange shafts in the axial direction.

This measure offers the following advantages:

– Reduces the housing noise level
– Provides higher active vehicle safety
– Permits more rapid cornering

Output shaft

Flange shaft

Compression
spring for flange
shaft

Final drive gear

Differential bevel gears

Differential of manual gearbox 02J
The differential of manual gearbox 02K is similar in design

SP18-14

29

Drive Shafts

The two manual gearboxes are used in the OCTAVIA with drive shafts featuring inner and
outer constant-velocity joints.
These are bolted at the inner joint to the flange shafts of the differential.

What is the difference in this case to the FELICIA?
The drive shafts used in the FELICIA feature an outer ball constant-velocity joint and an
inner tripod joint. Both drive shafts are solid shafts.

Inner tripod joint

Outer ball CV joint

FELICIA tripod drive shaft

Note:
OCTAVIA models with automatic transmission, however, feature a tripod drive shaft.
The tripod inner joint in this case is likewise bolted to the flange shafts of the differ­ential.

Pinion support

SP18-6

30

The drive shafts used on the SKODA OCTAVIA feature an inner and outer ball constant­velocity joint.

The left drive shaft is a solid shaft while the right drive shaft is designed as a hollow shaft.
Ball hub and joint housing of the inner joint are matched.

They must be marked before removing.
The assignment of the tracks must not be mixed up.

Inner ball CV joint

Outer ball CV joint

OCTAVIA ball CV joint drive shaft

Joint housing

Ball hub

Ball

SP18-7

31