NEW 6-Speed Manual Gearbox 02M forSP41_50Ever greater demands are made on modern cars in terms of function, driving comfort, safety, environmental compatibility and also their suitability for a sporty style of driving. That is a reason why cars undergo permanent further development and evolution. In addition to many other technical components this also is true for the gearbox. Gearboxes with more gears are, for example, quieter running and can be better adapted to the properties of different engines. By more effectively exploiting the available torque, they also indirectly contribute to a reduction in pollutant emissions. The 6-speed manual gearbox 02M is such a new development. It is a compact gearbox for transverse installation in the engine with 6 forward gears, adapted to four-wheel drive 4x4. The compact design has been achieved by using 1 input shaft and 2 output shafts. You can find out more regarding design and function of the gearbox in this Self Study Programme.2Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�GBContentsIntroduction Gearbox Mechanical Components Design The housing Diagram of gearbox The input shaft The 1st output shaft The 2nd output shaft The reverse idler shaft Differential and bevel box The double mesh Clutch control Power flow Shift Mechanism External shift mechanism Internal shift mechanism The selector movement The shift movement The reverse gear lock Sensors Indication of vehicle speed Reversing light switch F4 Test Your Knowledge 4 6 6 8 10 12 13 14 15 16 18 20 22 24 24 26 27 28 29 30 30 31 32Servicexxxxxxxxxxxxxxxx OCTAVIAServicexxxxxxxxxxxxxxxx OCTAVIAServicexxxxxxxxxxxxxxxx OCTAVIAService Servicexxxxxxxxxxxxxxxx OCTAVIA xxxxxxxxxxxxxxxx OCTAVIAService Servicexxxxxxxxxxxxxxxx OCTAVIA xxxxxxxxxxxxxxxx OCTAVIAS e r v i c eunless authorised You will find notes on inspection and by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� maintenance, setting and repair instructions in the Workshop Manual.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permittedXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXX XXXXXXXXGB3IntroductionGeneralWhat advantages does a 6-speed gearbox offer? Several reasons exist for using a gearbox with more than 5 forward gears. – Gearbox and engine can be better matched to each other. – The maximum engine torque is more effectively converted into acceleration. The engine can be operated in the rpm range offering the best economy. Improved fuel consumption is reflected in reduced exhaust emissions, which in turn contribute to an improvement in environmental compatibility. A higher level of driving comfort is achieved by improving the smooth running. 6-speed gearboxes combined with powerful engines also permit a sporty style of driving. Engine-gearbox harmonisation Utilisation of economic rpm ranges 6-speed gearbox permits better––––Smooth running and comfortProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Brief technical description – – – – – – – – – – – Gearbox designation: 02M Input shafts: 1 Output shafts: 2 Forward gears: 6 Reverse gears: 1 Maximum input torque: 350 Nm Type of installation: transverse Hydraulic clutch control - slave cylinder and release bearing form a single unit. Internal shift mechanism using shift shaft and shift rods with shift forks. Standardised cable shift mechanism. Gear oil: filled for life no changeImproved fuel consumptionReduced exhaust emissionsSporty style of driving4GBData sheetManually-operated 6-speed gearbox for 4x4 Gearbox code Engine assignmentNo. of teeth of driven gear z2 Ratio i = No. of teeth of driving gear z1 FBS 1,9 l/74 kW TDI z2 z1 11 19 29 37 34 27 14 11 i 3,818 2,105 1,310 0,919 0,912 0,757 4,630 4,200 3,3161st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse42 40 38 34 31 28 23 31Final drive unless 1st output shaft 63 authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept15 any liabilitywith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permittedFinal drive 2nd output shaft Detection of distance driven and vehicle speed Gear oil specification Gear oil change Clutch control Assignment of rear final drive/Code6319 electronic G51 SAE 75W90 (synthetic oil) filled for life hydraulic EULThe gearbox with gearbox code FBS is assigned in this case to engine 1.9 l/74 kW TDI. The gear steps have been specifically harmonised to this engine.Note: The gearbox code letters are also listed in the data stickers of the vehicle.GB5Gearbox Mechanical ComponentsDesignIn a conventional gearbox it is the input shaft which transmits the torque to an output shaft on which the various shift gears for the individual gear steps are arranged. The more shift gears there are arranged on a gearbox shaft, the longer it becomes and the longer also is the gearbox itself. In the case of a so-called compact gearboxes which also includes the manual gearbox 02M, use is made of not only one, but two output shafts. This makes it possible to significantly reduce the overall length, and at the same time to achieve savings in terms of material and costs.Shift shaftInput shaft1st output shaftProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�2nd output shaftDifferential6GBThe shift gears for the individual speeds are distributed over the two output shafts as follows: – – 1st output shaft forward gears 1 to 4 2nd output shaft forward gears 5, 6 and reverseReverse gear also includes a reverse idler shaft with two gearwheels which reverse the direction of rotation (in the illustration the reverse idler shaft is concealed by the input shaft).Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Bevel box for fourwheel drive 4x4SP41_03GB7Gearbox Mechanical ComponentsThe housingconsists of 3 principal components (gearbox housing, clutch housing and the housing for the bevel box). The shift cover seals off the gearbox housing to the top. In order to achieve a lightweight construction, all of the housing components are manufactured from a magnesium/aluminium alloy.Clutch housingNote: You can find detailed information regarding the conditions which must be observed when using parts manufactured from magnesium, in the Self Study Programme No. 37.Housing for bevel boxSP41_58Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�8GBShift coverGearbox housingSP41_59SP41_01 SP41_57GBProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�9Gearbox Mechanical ComponentsDiagram of gearboxGearbox housingReverse idler shaft2nd output shaft, 5th and 6th gearInput shaftProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�1st output shaft, 1st to 4th gearThe 02M manual gearbox is a compact design for 4x4 drive offering 6 gears. It is a 3-shaft gearbox with an additional reverse idler shaft. The gearwheels on the input shaft, on the output shafts and on the reverse idler shaft are helical gears and are constantly meshed.Left flange shaftFinal drive gearDifferential Speedometer sensor10GBClutch housing Reverse idler shaft Input shaft2nd output shaft1st output shaftFinal drive gearDiagram of positions of shaftsNote: The diagram of the gearbox illustrates shafts in one plane.1st to 4th gear are shifted on the 1st output shaft, 5th and 6th gear on the 2nd output shaft. Reverse gear is shifted on the 2nd output shaft. All the forward gears as well as reverse are synchronised.Bevel box Bevel boxThe torque is transmitted through one of the two output shafts to the final drive gear, the differential and on from there through the left and right flange shafts to the front wheel drive. For four-wheel drive the torque is transmitted through the bevel box, the adjoining propshaft and a Haldex clutch to the rear final drive.SP41_02Note: You can find detailed information regarding the 4x4 drive train with Haldex clutch in SSP 29.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted To rearunless axleauthorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�GB11Gearbox Mechanical ComponentsThe input shaftThe input shaft is mounted in a taper roller bearing both in the clutch housing as well as in the gearbox housing.5th speed gearSP41_063rd/4th speed and 6th speed gear1st speed and reverse gear splines Deep hole bore for reducing weightProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�SP41_05Taper roller bearing Taper roller bearing 2nd speed splinesThe splines for 1st, 2nd and reverse gear are part of the input shaft. The gearwheels for 3rd to 6th speed are shrink-fitted to form a fixed part of the input shaft. The input shaft has a deep hole bore to reduce weight.12GBThe 1st output shaftIn the same as the input shaft, it is mounted in a taper roller bearing both in the clutch housing and in the gearbox housing. The shaft has a bore extending axially with the aim of reducing weight.3rd speed change gear 4th speed change gear1st speed change gear 2nd speed change gearSP41_08Splines to final driveBore for reducing weightTaper rollerTaper Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability SP41_07 to thespeed correctness of information in this document. Copyright by Š KODA AUTO A. S.� bearing with respect 3rd/4th synchroniser body 1st/2nd speed synchroniser bodyroller bearingThe splines to the final drive are part of the output shaft. The gears of 1st to 4th speed are loose (which is why they are also known as "movable gears") and run in needle bearings. By virtue of their function they are also known as shift gears. The two synchroniser bodies of 1st/2nd and 3rd/4th gear are firmly connected to the output shaft by longitudinally slotted splines. Retaining rings hold them in their position.The movable gears of the output shaft are constantly meshed with the matching splines of the input shaft. In view of the fact, however, that they are not firmly connected to the output shaft so long as no gear is engaged, they do not transmit any torque in this state. As soon as one of the gears is engaged, the corresponding movable gear is connected to the output shaft.GB13Gearbox Mechanical ComponentsThe 2nd output shaftIt too runs in a taper roller bearing both in the clutch housing as well as in the gearbox housing. The 2nd output shaft has a bore running continuously axially to reduce weight.5th speed change gear6th speed change gear SleeveReverse change gearSP41_10Splines to final driveBore for reducing weightSP41_09Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Taper roller bearing5th/6th speed synchroniser bodyReverse gear synchroniser bodyTaper roller bearingThe splines to the final drive are part of the output shaft. The gears of 5th and 6th speed and reverse gear are loose (which is why they are also known as "movable gears") and run in needle bearings. By virtue of their function they are also known as shift gears. The synchroniser bodies of 5th and 6th and reverse gear are firmly connected to the output shaft by longitudinally slotted splines. Retaining rings hold them in their position.The movable gears of the output shaft are constantly meshed with the matching splines of the input shaft. In view of the fact, however, that they are not firmly connected to the output shaft so long as no gear is engaged, they do not transmit any torque in this state. As soon as one of the gears is engaged, the corresponding movable gear is connected to the output shaft.14GBThe reverse idler shaftThe reverse idler shaft for reverse gear is mounted in a needle sleeve both in the clutch housing and in the gearbox housing. The reverse idler shaft has a bore running through axially for reducing weight.GearSP41_12SplinesBore for reducing weightNeedle sleeve Needle sleeveSP41_11The reverse idler shaft is provided with the splines for reverse gear and a gearwheel which is firmly connected to the shaft by shrink-fitting.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�GB15Gearbox Mechanical ComponentsDifferential and bevel boxThe differential, together with the manual gearbox and the bevel box, form a single unit. It is mounted in taper roller bearings in the gearbox housing and clutch housing. The gearbox housing is sealed to the outside at the left flange shaft by means of a sealing ring. The bevel box forms the end cover at the opposite side.Connecting sleeve Splines of 1st output shaft (splines of 2nd output shaft concealed) Clutch housing Final drive gearGearbox housingSealing ringLeft flange shaftProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Taper roller bearingDifferential housingThe final drive gear is firmly riveted to the differential housing and is constantly meshed with the splines of the two output shafts.Speedometer sensor G22Note: Always refer to the information in the Workshop Manual for setting operations at the bevel box.16GBThe bevel box features two flanges positioned at right angles to each other: – – the right flange shaft for the front-wheel drive and the output flange pointing toward the rear axle for driving the propshaft (rear final drive).Hollow shaft Taper roller bearings Head bevel gearSP41_16Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Sealing ringRight flange shaftNeedle bearing (polygon bearing)Shank bevel gear Taper roller bearings Sealing ringSP41_15Drive to rear axleOutput flangeThe head bevel gear is connected by means of the connecting sleeve to the differential, which drives the former. It in turn is meshed at right angles to the shank bevel gear and directs the power flow from the differential on to the rear axle.The right flange shaft is longer than the left flange shaft. It is connected on the left to the differential and its shank runs in a needle bearing (polygon bearing) in the bevel box.The bevel box is sealed to the outside at the right flange shaft and at the output flange for the rear-wheel drive by means of sealing rings.GB17Gearbox Mechanical ComponentsThe double meshReplacing the single output shaft conventionally fitted to a gearbox by two output shafts of a more compact design, is in itself not sufficient to achieve a particularly compact design of gearbox. It also calls for a simple technical solution for transmitting the torque to the two output shafts. This task on the 02M gearbox is solved by employing the so-called "double mesh".Note: Using the double mesh makes it possible to transmit the force for 2 gears at a time with only one set of splines of the input shaft.Change gear of 2nd output shaftInput shaft Change gear of 1st output shaftSP41_55With the double mesh principle it is only The change gears (movable gears) of the necessary to have one set of splines on the output shafts which are involved in a double input shaft in order to drive both a change mesh have different diameters and thus also gear (movable gear) of the 1st output shaft a different number of teeth to match the gear as well as a change gear of the 2nd output step. shaft (in the case of double meshProtected with the by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability The change gears (movable gears) of the reverse idler shaft, the 2nd meshunless is achieved with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1st output shaft have a larger diameter than by means of the gear which is mounted on the those of the 2nd output shaft. reverse idler shaft).18GBThe 02M gearbox has 3 double meshes: – 1st speed change gear on 1st output shaft and gear of reverse idler shaft with the splines of the input shaft (red), – 4th speed change gear on the 1st output shaft and 6th speed change gear on the 2nd output shaft with the splines of the input shaft (blue), and – the splines of the 1st and 2nd output shafts with the final drive gear (green).Final drive gear1st speed change gear 4th speed change gear 1st output shaftSP41_14Reverse idler shaftInput shaftProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 2ndoutput shaftSP41_136th speed change gearGB19Gearbox Mechanical ComponentsClutch controlThe clutch control is a hydraulic version. The slave cylinder and the release bearing form a single unit which is bolted to the clutch housing. New! Clutch release lever and separate release bearing with neck bearing are no longer required. The hydraulic system of the clutch operates with brake fluid and is connected to the brake fluid reservoir.6-speed manual gearbox 02M 4x4Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Brake fluid with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�SP41_51Slave cylinder with release bearingNote: Slave cylinder and release bearing form a single unit and can only be replaced together.20GBSlave cylinder and release bearing The slave cylinder and guide sleeve are firmly connected to each other. The piston of the release bearing moves in an axial direction in the slave cylinder and on the guide sleeve. Two seals positioned one behind the other and which are positively connected to the piston, seal off the release bearing to the slave cylinder and to the guide sleeve. Balls enclosed in a cage and which in turn support the outer race, run on the inner race of the release bearing which is firmly connected to the piston. As a result of the spring action of the compression spring the outer race is constantly pressed against the diaphragm spring of the clutch and also rotates with it. A sleeve positively connected to the inner race, protects the release bearing. The slave cylinder is supplied with brake fluid through a special feed. When the clutch pedal is operated, pressure is produced by the familiar master cylinder at the clutch pedal. The pressurized brake fluid which flows in, pushes the release bearing axially out of the slave cylinder in the direction of the clutch, and the clutch is operated.Pressure plateFlywheel Clutch platesDiaphragm springBrake fluidGuide sleeveClutch housing Seals Slave cylinder Piston SleeveCompression spring Inner race of release bearingGBClutch operatedProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Clutch not operatedOuter race of release bearingSP41_5221Gearbox Mechanical ComponentsPower flowRSP41_191SP41_202SP41_21Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�35R1SP41_2722246GB3SP41_22Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�5SP41_244SP41_236SP41_25Power flow in the gearbox The engine torque is passed through the input shaft into the gearbox. Depending on the gear engaged, the torque is guided by the relevant pair of gears to the 1st or 2nd output shaft and by the latter to the final drive gear. When reverse gear is engaged, this is achieved additionally through the reverse idler shaft. Torque and engine speed are now active at the driven wheels in line with the gear engaged.GB23Shift MechanismExternal shift mechanismThe gearbox features a cable shift in order to eliminate the transmission of vibrations and twisting from the engine area. Two cables form the link between the gearshift lever inside the car and the gearbox.Shift movementSelector movementGearbox shift leverRelay leverSliding shoeLocking pinSP41_28The two cables transmit the selector and shift movement of the gearshift lever to the shift shaft. The mechanism (relay lever and gearbox shift lever with balancing weight) converts the forward and back movements of the 2 cables into up and down as well as rotational movements of the shift shaft.The shift shaft can be fixed in a predefined position by means of a locking pin for setting the shift mechanism. This greatly simplifies the task of setting the mechanism.24Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�GBA 4-gate shift has been selected for the gearbox in which reverse gear is positioned at the front left in the shift pattern.The position of the other gears is the same as on the familiar standard shift.Selector movement Shift cable Shift movement56 3 1 R42Gearshift leverSP41_30SP41_29Shift housingSelector cableProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�The familiar depress pressure lock is used as a safeguard against reverse gear being inadvertently engaged (page 29).Note: You can find detailed information regarding the setting of the cable shift in the Workshop Manual.GB25Shift MechanismInternal shift mechanismThe shift movements are transmitted through the shift shaft into the gearbox. The shift shaft is guided in the shift cover and in a mounting inside the gearbox. The internal mounting is attached to the gearbox housing by an end cover. Both ends of the shift rods with the shift forks for gears 1 to 6 run in a bearing bush both in the clutch housing as well as the gearbox housing. Spherical sleeves are used for mounting the shift rod ends.Shift gate Shift shaftShift coverShift finger for 1st to 4th gearShift finger for reverseShift finger for 5th and 6th gear Shift rod with shift fork for 1st and 2nd gear Shift shaft Shift rod with shift fork for 3rd and 4th gear Internal mountingSP41_53The shift fork for reverse gear is mounted in spherical sleeves on a stud which is attached in the clutch housing. When a gear is shifted, the shift forks are moved by one each of the two shift fingers.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. doesThe not guarantee accept are any liability shift or forks moved with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�complete with the shift rods in the axial direction of the shift rods, the shift fork for reverse gear is moved axially on the stud in the clutch housing.SP41_31Reverse gear shift fork Stud in housingShift rod with shift fork for 5th and 6th gear26GBThe selector movementThe selector movement which is initiated at the gearshift lever (gearshift lever moved to right or left) is transmitted through the selector lever to the selector cable and converted into a forward and back movement. The selector angle plate is pivot-mounted on a bearing pin.SP41_34Selector movement Shift lever Shift lever guide Ball guideBearing pinRelay leverSP41_33Selector cable Selector angle plate Shift shaft Sliding sleeveThe forward and back movement of the selector cable is converted into an up and down movement of the shift shaft by means of the relay lever mounted at the gearbox. The selector cable is attached to the relay lever for this purpose. The relay lever is pivotmounted at the gearbox and flexibly connected by means of a sliding shoe to the shift shaft. The effect which this up and down movement has in the gearbox is that the relevant shift Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted finger is guided into the driver of the particular unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. � the selected gear which is to be Shift fork with shift fork of Shift finger driver engaged (1st/2nd gear; 3rd/4th gear; 5th/6th SP41_32 gear or reverse).Output shaftGB27Shift MechanismThe shift movementThe shift lever movement is transmitted through the shift lever guide (forward and back movement of the shift lever) to the shift cable. If the shift lever is moved forward or back in the direction of the individual gears, the shift cable is pulled or pushed in the opposite direction of the movement of the shift lever.SP41_37Shift movementShift lever guide Shift lever Ball guideProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�Gearbox shift leverSP41_36Shift cableSliding sleeveAs a result of the forward and back movement of the shift cable during the gearshift, the shift shaft is rotated about its axis. As a consequence of the moving sliding shoe, the relay lever for the selector movement at the gearbox remains in its selected position. In the gearbox, as this rotary movement is taking place, the relevant shift finger which is meshed into the recess of the driver of the shift fork, moves the shift fork sideways. This ensures that the sliding sleeve is pushed simultaneously onto the relevant change gear and the selected gear is engaged.Shift shaftOutput shaft Shift fork with driverSP41_35Shift finger28GBReverse gear lockA depress pressure lock acts as a safeguard to prevent reverse gear being inadvertently engaged. The depress pressure lock is integrated in the shift housing. It must first of all be overcome by the driver before it is possible to select and engage reverse gear.2SP41_39Shift lever Compression spring1Shift lever guideShift housingCompression spring Shift lever guide Shift lever1 2depress continue selection2SP41_38During the normal selection movement of the forward gears, the locking lug of the shift lever strikes against the lock (part of the shift housing).SP41_40Lock Locking lug1When the driver pushes the shift lever down against the compression spring, the lever slides down through the spherical-shaped shift lever guide, the locking lug is now located further down than the lock.SP41_412During the subsequent selector movement for reverse gear, the lock is bypassed, it is now possible to engage reverse gear.SP41_42Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability the shift lever is released the with respect to the When correctness of information in this document. Copyright from by ŠKODA AUTO A. S.�depress movement, the compression spring pushes it back up again into the shifted position and holds it in the reverse gear position.SP41_43GB29SensorsIndication of vehicle speedRecesses (reference marks) provided on the differential housing generate, in a similar way to a pulse generator gear, the signals required at the speedometer sensor G22 for determining the vehicle speed. The speedometer sensor G22 is installed from the outside into a hole in the gearbox housing.Reference marks on differential housingProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability sensor G22 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�SpeedometerSP41_44The sensor operates on the Hall principle. The electric pulses of the sensor flow to the control unit in the dash panel insert where they are processed for indicating the vehicle speed and the distance travelled. This ensures a high level of accuracy for the indications, quiet running and insensitivity to temperature variations.G22J218G21SP41_45Electric circuitJ218D +15 G21 G22 J218Ignition/starter switch, terminal 15 Speedometer Speedometer sensor Control unit in dash panel insertD +15G21G2231SP41_4630GBReversing light switch F4The switch for the reversing lights is screwed into the side of the gearbox housing.Shift shaftWhen reverse gear is selected, the shift gate, together with the shift shaft, is moved sufficiently far into the gearbox so that the pushbutton of the reversing light switch F4 engages in a recess at the lower edge of the shift gate. During the subsequent gearshift operation, the shift gate pivots about its axis, the pushbutton is moved out of the recess and the switch is operated. The circuit to the reversing lights is closed.Shift gateReversing light switch F4 PushbuttonSP41_47RecessElectric circuit D +15 F4 M16 M1730 31Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Ignition/starter switch, terminal 15 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Reversingwith light switch respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Bulb for left reversing light Bulb for right reversing lightD +15 S7 10AF4M16M173131SP41_48GB31Test Your KnowledgeWhich answers are correct? Sometimes only one. But perhaps also more than one – or all of them! Please complete the blank spaces.1.A 6-speed gearbox offers the advantage of A. B. C. quieter running. higher vehicle speed. improved environmental compatibility.2.Why was the 02M gearbox for 4x4 designed with two output shafts? ................................................................................................................................. ................................................................................................................................. .................................................................................................................................3.How are the gears assigned to the 1st and 2nd output shafts? 1st output shaft .................................................................................................... 2nd output shaft ....................................................................................................4.Draw in the power flow for 6th gear.SP41_60Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�32GB5.What is a "double mesh"? ................................................................................................................................. ................................................................................................................................. .................................................................................................................................6.The gearbox has A. B. C. one double mesh. two double meshes. three double meshes.7.Hollow-boring of the gearbox shafts is designed to A. B. C. enhance the torsional stiffness. ensure quiet gearbox running. reduce the weight of the gearbox.8.The bevel box for additionally transmitting the torque to the rear axle A. B. C. is a stand-alone unit and positioned downstream of the differential. is part of the differential. forms a single unit together with the differential and the gearbox.9.The clutch control is performed A. B. C. hydraulically by means of a clutch release lever and a separate release bearing with neck bearing. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A.and S. does not guarantee or accept any liability by means of a hydraulic unit, consisting of slave cylinder release bearing. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� mechanically by means of a clutch release lever which moves the release bearing mounted on the input shaft axially.GB33Answers: 1. 2. 3. 4.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�A.; C. Because using two short output shafts in comparison to a single long output shaft makes it possible to achieve a shorter overall length. 1st output shaft: 1st - 4th gear 2nd output shaft: 5th/6th and reverse gear65.SP41_256. 7. 8. 9.In the case of a double mesh the single set of splines of the input shaft is meshed both with a change gear (movable gear) of the 1st output shaft as well as with a change gear of the 2nd output shaft. In this case, though, there is always only one gear shifted (on the respective output shaft). C. C. C. B.34Test Your KnowledgeGBNotesProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�GB35