Manual gearbox 02S and clutch Skoda Octavia 3

Transmission 6-speed manual 02S — general information
Designation of the KP The 6-speed manual transmission 02S is installed in combination with 4-cylinder engines. Location at the checkpoint Letter designation and date of production "see arrow 1". Designation of the KP...

General installation diagram — pedal mechanism
1. Master cylinder 2. Support sleeve 3. Clamp: To remove and install the hose line, pull the clamp out until it stops 4. Seal: self-adhesive; replace after removing the clutch master cylinder; is glued to the clutch...

Removal and installation the top dead center spring
Disconnect the battery ground wire. If present, remove the driver's knee airbag "1". Remove the deflector "1" in the footwell on the driver's side. Remove the diagnostic interface for the data bus from the holder "J533"...

Removal and installation the clutch pedal
Disconnect the battery ground wire. If there is a bracket in the area, remove the "arrow" mount together with the parking autopilot ECU "J446" and move it to the side. Remove the top dead center spring, or top dead...

Removal and installation the clutch pedal support bracket
Remove the air filter housing assembly if it interferes with access to the clutch hydraulic lines. Disconnect the battery ground wire. Remove the battery. Caution! Risk of brake fluid leakage. When performing the...

Removal and installation the clutch master cylinder
Note: Before replacing a clutch master cylinder that is suspected of being defective, first carry out a check using the -Guided Fault Finding-. When working in the footwell, protect the floor covering from escaping...

Removal and installation the support bushing
Disconnect the battery ground wire. Squeeze the "arrow" clamps and pull pin "1" to the right. Turn the master cylinder pushrod so that notches "1" or pin "2" become visible. Notches "1" and pin "2" are directed in the...

Removal and installation the clutch pedal position sensor «G476»
Move the driver's seat as far back as possible. Disconnect the connector "arrow" on the clutch pedal position sensor "G476". Open the "arrow" retainer of the clutch pedal position sensor "G476" "2" on the clutch master...

General installation diagram — hydraulic system
1. Hex head screw 2. Bleed nipple, 4.5 Nm 3. Rubber cap 4. Hose for work after switching off 5. Hydraulic brake fluid reservoir 6. Seal: Must be in the hose for operation after shutdown 7. Clutch master cylinder 8....

Disconnecting/connecting clutch drive lines
Open the clamp "3" with a screwdriver and remove the hose pipe "1" from the fitting "4". Connection Note: Instead of sealing ring "2" a circular sealing ring can be installed. Replace the damaged sealing ring "2". Press...

Checking the hydraulic clutch drive
Note: If the master cylinder or slave cylinder has to be replaced due to a fault, first check the hydraulic clutch drive. If the slave cylinder is removed with the hose line connected to the gearbox, do not press the...

Checking the entire hydraulic system for leaks
Inspect the following clutch hydraulic drive components for leaks. Check the brake fluid level in the hydraulic brake drive reservoir. The after-run hose between the hydraulic brake drive reservoir and the master...

Removal and installation the clutch slave cylinder
Note: Before replacing a clutch master cylinder that is suspected of being defective, first carry out a check using the -Guided Fault Finding-. If the slave cylinder is removed with the hose connected to the gearbox, do...

Removal and installation of clutch drive pipes
Remove the air filter housing assembly if it interferes with access to the clutch hydraulic lines. Remove the battery and battery bracket. All Caution! Risk of brake fluid leakage. When performing the following work,...

Bleeding air from the clutch drive
Note: After working on the hydraulic clutch drive, the system must be bled. When performing the following work, make sure that no brake fluid gets on the gearbox. Preliminary bleeding of the system is not required!...

Repair of the clutch release mechanism — sequence
1. KP 2. Spherical pin, 25 Nm: The original grease must be removed from the contact surface of the clutch release lever; lubricate with consistent grease "G 000 100" 3. Drive shaft sealing ring: replace 4. Guide bush:...

Removal and installation the clutch release lever with release bearing
Disconnect the spring "see arrow 1". Remove the clutch release lever "see arrow 2" and the release bearing. Install in reverse order. Removal and installation the release bearing Remove the locking tabs "see arrows" on...

General installation diagram — repair of the clutch of the company «Sachs»
Note: Before replacing the clutch disc and pressure plate, take into account the transmission fault finding - complaints about the clutch and clutch drive. Replace clutch discs and pressure plates with damaged or loose...

Removal and installation the clutch of the company «Sachs»
To prevent deformation of the clutch pressure plate when removing (which leads to jerks when starting off) the clutch pressure plate mounting screws should be loosened as follows: To loosen the screws, install the...

General installation diagram — clutch repair by LuK
Note: Before replacing the clutch disc and pressure plate, take into account the transmission fault finding - complaints about the clutch and clutch drive. Replace the clutch disc and pressure plate with damaged or...

Removal and installation of the clutch of the company «LuK»
To prevent deformation of the clutch pressure plate when removing (which leads to jerks when starting off) the clutch pressure plate mounting screws should be loosened as follows: To loosen the screws, install the...

Transmission Troubleshooting — Clutch and Clutch Drive Complaints
Before each clutch repair, it is essential to check the owner's complaints and take them into account. In each individual case, it should be determined whether it is really a complaint about the clutch or whether the...

General installation diagram — shift handle with gear shift boot
1. Shift knob: with cover; the shift knob and the boot are not separated from each other; the gearshift lever plaque can be separated from the shift knob, for example, with a screwdriver; always change together 2. Case:...

Removal and installation the shift handle with gear shift boot
Place the release tool "T30098" in the middle between the decorative frame and the gearshift lever boot "arrow 1". Carefully press the gearshift lever boot away from the center console using the release tool "T30098"...

General installation diagram — switching mechanism
Note: Lubricate all bearing and contact surfaces with grease "G 000 450 02". 1. Overlay: bend the tabs to remove; is subject to mandatory replacement 2. Seal: must be replaced 3. Gear shift lever 4. O-ring with circular...

Repair of the switching mechanism
Removal and installation the retaining ring Hold the gearshift lever "2". Press the spacer sleeve "3" in the direction of the arrow. Remove the lock washer "1". Removal and installation the damper "see arrow" Push the...

Disassembly and assembly of the switching mechanism
Remove the shift mechanism. Bend the tabs "see arrows" of the shift mechanism cover with a screwdriver and remove the cover. Remove the seal. Remove lock washers -2 and 3- (lock washers -1 and 4- are now missing), the...

General installation diagram — drive cables
Note: Lubricate all bearing and contact surfaces with grease "G 000 450 02". 1. Gear shift cable; disconnect from the shift lever guide on the gear shift mechanism; press into the guide of the gearshift lever on the...

Installing the gear shift lever
When installing the gear shift lever, make sure that the gap between the teeth "see arrow A" matches the interrupted pitch of the gear shift rod teeth "see arrow B". Shift lever/intermediate lever installation position...

Removal and installation the shift mechanism
Disconnect the battery ground wire with the ignition off. Remove the air filter if it is installed above the gearbox. Open the clamp "see arrow" and remove the shift handle together with the cover. Remove the ashtray....

Removal and installation the gear shift cable and gear selection cable
Remove the shift mechanism: bend the tabs "see arrows" of the shift mechanism cover with a screwdriver and remove the cover. Remove the seal. Remove lock washers -2 and 3- (lock washers -1 and 4- are now missing), the...

Adjusting the switching mechanism
Note: The conditions for correct adjustment of the shift mechanism are as follows. Gearbox, clutch and clutch drive are in perfect condition. The gearshift mechanism moves smoothly. The controls and transmission...

Gearbox removal — front wheel drive
Remove the engine cover. Note: All bandages that are released or cut during removal must be reinstalled in the same places during installation. Additional work must be performed when disconnecting and connecting the...

Tightening torques
Mounting the engine-gearbox unit on a car with a 1.4 l/103 kW FSI engine 1) Full thread screw M8. Pos. "A": Unloading bushings for centering Mounting the engine-gearbox unit on a car with a 1.8 l/132 kW ISI engine 1)...

Installation of the control unit
The gearbox is installed in the reverse order of removal. Ensure that the vehicle units are installed without stress. Press the clutch release lever before installing the gearbox to the gearbox housing and secure it...

Checking the transmission oil level
Note: The gearbox oil level can only be checked by completely draining the transmission oil and then refilling it. To drain the transmission oil, remove the gearbox shift fork shaft journal. To prevent the shift fork...

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Octavia 3 (2013-2019)