Skoda Octavia Tour 1U Repair Manual - PDF DOWNLOAD

Service

Workshop Manual Octavia 1997 ➤ Axles, steering Edition 11.2011

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Service Department. Technical Information

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Service List of Workshop Manual Repair Groups

Repair Group 40 - Front suspension 42 - Rear suspension 44 - Wheels, tyres, vehicle geometry 48 - Steering

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.�

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 ŠKODA AUTO a. s.

D3E801B9566

Octavia 1997 ➤ Axles, steering - Edition 11.2011

Contents 40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Repairing front wheel suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of components: Assembly carrier, axle link, anti-roll bar . . . . . . . . . . . . . . . . . .

Removing and installing the track control arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressing out and in the bearing for the track control arm . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressing out and in rubber-metal bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of components of the wheel bearing, suspension strut, drive shaft and brake . .

Repairing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting the steering joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing the steering joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove and install suspension strut and wheel bearing housing . . . . . . . . . . . . . . . . . . . .

Repairing the suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting the shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposing of the shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing a drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing drive shaft with outer and inner CV joint VL 3700 . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting outer CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting inner CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint . . . . . . . . . . . . . .

Disassembling and assembling the tripod joint AAR 2900 . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint . . . . . . . . . . . . . .

Disassembling and assembling the tripod joint AAR 2000 . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 4 9 10 12 13 17 19 20 22 27 29 30 32 36 39 45 46 48 50 53 56

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4

Repairing rear axle - drum brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Removing and installing rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Summary of components of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Replacing the rubber-metal bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Disassembling and assembling shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Repairing rear axle - disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Removing and installing rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Summary of components of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Protected by Replacing the rubber-metal bearing . .copyright. . . . . .Copying . . . . .for. private . . . .or. commercial . . . . . . purposes, . . . . . .in.part . . or. in. .whole, . . . is. not . . permitted 89 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Removing and installing shock absorber/spring . . . of. .information . . . . . .in.this . . document. . . . . . .Copyright . . . . . by. .ŠKODA . . . . AUTO . . . A.104 with respect to the correctness S.� Disassembling and assembling shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Repairing the wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Repairing the wheel bearing, vehicles with front-wheel drive - drum brake . . . . . . . . . . . . 106 Repairing the wheel bearing - disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Repairing rear axle (vehicles with four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Rear axle with four-wheel drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Trailing arm and suspension arm - Summary of components . . . . . . . . . . . . . . . . . . . . . . 122 Pressing out and pressing in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Removing and installing rubber-metal bearing for trailing arm . . . . . . . . . . . . . . . . . . . . . . 130 Removing and installing guide joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Removing and installing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Contents

i

Octavia 1997 ➤ Axles, steering - Edition 11.2011 5.5 6 6.1 6.2 6.3 7 7.1 7.2

Removing and installing suspension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Summary of components - Assembly carrier with final drive . . . . . . . . . . . . . . . . . . . . . . . . 142 Removing and installing assembly carrier with final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Removing and installing rubber-metal bearing for assembly carrier . . . . . . . . . . . . . . . . . . 146 Removing and installing rubber-metal bearing for final drive . . . . . . . . . . . . . . . . . . . . . . . . 148 Repairing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Removing and installing a drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Repairing drive shaft with CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Chassis - Specified values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Nominal values front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Specified values rear axle - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Specified values rear axle - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Vehicle data sticker and PR numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Vehicle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Measurement preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Chassis terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Nominal values for vehicle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Checking the transversal inclination of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Checking the camber on the front axle, if necessary take the mean . . . . . . . . . . . . . . . . . . 170 Checking the camber on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Checking the track on the rear axle, if necessary taking the mean/adjusting . . . . . . . . . . 171 Checking the track on the front axle, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 172 Checking the left and right steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Calculation of the misalignment on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Check position of steering wheel, align if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4 4.1 4.2 4.3 5 5.1

ii Contents

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Hydraulic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Protected by copyright.

Copyingwheel for private or commercial Steering column and steering with airbag purposes, . . . . in. .part . .or. in. whole, . . . .is.not . .permitted . . . . . . . . . . . . . . . 178 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Check the steering for damage . . document. . . . . . .Copyright . . . . . by. .ŠKODA . . . . AUTO . . . .A..S.� . . . . . . . . . . . . . . 178 with respect column to the correctness of information.in. this Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Removing and installing the ignition lock housing with the steering column mounted . . . . 188 Summary of components of power-steering gear - LHD vehicles . . . . . . . . . . . . . . . . . . . . 190 Removing and installing hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Removing and installing the power-steering gear - LHD vehicles . . . . . . . . . . . . . . . . . . . . 193 Repairing power-steering gear (ZF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Modified track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Modified track rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Disposing of the power-steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Adjusting the power-steering gear (ZF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Check the hydraulic oil level of the power-assisted steering, top up if necessary . . . . . . . . 206 Draining, filling and bleeding the power-assisted steering system . . . . . . . . . . . . . . . . . . . . 207 Checking the power steering system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Power steering noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Summary of components of power-steering gear - RHD vehicles . . . . . . . . . . . . . . . . . . . . 211 Removing and installing hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Removing and installing the power-assisted steering gear - RHD vehicles . . . . . . . . . . . . 214 Repairing power-steering gear (ZF) - RHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Summary of components: Vane pump for power-assisted steering . . . . . . . . . . . . . . . . . . 222 Summary of components for the vane pump located at the top and bottom . . . . . . . . . . . . 222

Octavia 1997 ➤ Axles, steering - Edition 11.2011 5.2 5.3 6 6.1 6.2 6.3

PAS pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Check the feed pressure of the vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Vehicles with vane pump located at the top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Vehicles with vane pump located at the bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Disposing of the vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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.�

Contents

iii

Octavia 1997 ➤ Axles, steering - Edition 11.2011

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.�

iv Contents

Octavia 1997 ➤ Axles, steering - Edition 11.2011

40 –

Front suspension

1

Repairing front wheel suspension

Summary of components: Assembly carrier, axle link, anti-roll bar ⇒ page 2 Removing and installing the track control arm ⇒ page 4 Pressing out and in the bearing for the track control arm ⇒ page 9 Removing and installing the assembly carrier ⇒ page 10 Pressing out and in rubber-metal bearing ⇒ page 12 Summary of components of the wheel bearing, suspension strut, drive shaft and brake ⇒ page 13 Repairing wheel bearing housing ⇒ page 17 Inspecting the steering joint ⇒ page 19 Removing and installing the steering joint ⇒ page 20 Remove and install suspension strut and wheel bearing housing ⇒ page 22 Repairing the suspension strut ⇒ page 27 Inspecting the shock absorber ⇒ page 29 Disposing of the shock absorber ⇒ page 30 Removing and installing drive shaft ⇒ page 32

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.�

1. Repairing front wheel suspension

1

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.1

Summary of components: Assembly carrier, axle link, anti-roll bar Note

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.�

♦ When moving vehicles with drive shaft removed, it is advisable

to install an external joint instead of the drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.

♦ Welding and straightening work is not allowed on the bearing

and wheel control components of the wheel suspension.

♦ Self-locking nuts must always be replaced. ♦ Always replace corroded self-locking nuts and screws.

2 Rep. gr.40 - Front suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - track control arm ♦ removing and installing ⇒ page 4 ♦ Oblong holes are not inten‐ ded for camber adjustment!

2 - 15 Nm + 90° 3 - Coupling rod ♦ coupling rods of the same version must be present on one axle ♦ Assignment ⇒ Electronic Catalogue of Original Parts 4 - 15 Nm + 90° ♦ replace after each removal 5 - Coupling rod ♦ only for anti-roll bars with a diameter of 23 mm ♦ replace with steel version ♦ coupling rods of the same version must be present on one axle ♦ Assignment ⇒ Electronic Catalogue of Original Parts 6 - Front bearing for track con‐ trol arm ♦ pressing in and pressing out ⇒ page 9 7 - 70 Nm + 90° ♦ replace after each removal 8 - Pendulum support 9 - 40 Nm + 90° ♦ replace after each removal 10 - 40 Nm + 90° ♦ replace after each removal 11 - 20 Nm + 90° ♦ replace after each removal 12 - Assembly carrier 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 ♦ removing and installing ⇒ page 10 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ The repair of the thread for the screwed connection of the front track control arm is not permissible!

13 - Self-locking nut ♦ replace after each removal ♦ M10 - 15 Nm + 90° ♦ M12 - 90 Nm 14 - Anti-roll bar ♦ to remove and install lower assembly carrier

1. Repairing front wheel suspension

3

Octavia 1997 ➤ Axles, steering - Edition 11.2011 15 - Rubber bearing 16 - 25 Nm 17 - Clamp 18 - Coupling rod ♦ mount the spherical head with the long joint stub -A- (top) to the spring cap ♦ mount the spherical head with the short joint stub -B- (bottom) to the anti-roll bar ♦ Assignment ⇒ Electronic Catalogue of Original Parts 19 - Nut, 90 Nm ♦ replace after each removal 20 - Rubber-metal bearing ♦ pressing in and pressing out ⇒ page 12 21 - Self-locking nut ♦ replace after each removal 22 - 100 Nm + 90° ♦ replace after each removal 23 - Rear bearing for track control arm ♦ Fitting position ⇒ page 10 ♦ pressing in and pressing out ⇒ page 10 24 - 100 Nm + 90° ♦ replace after each removal 25 - 70 Nm + 90° ♦ replace after each removal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

26 - Lock washer 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.�

♦ replace after each removal 27 - 20 Nm + 90° ♦ replace after each removal 28 - Steering joint ♦ check ⇒ page 19

♦ Inspect rubber bellows for damage, if necessary replace ♦ removing and installing only in combination with the wheel bearing housing ⇒ page 20 ♦ mark fitting position before removal, set in the middle of the oblong hole when replacing the track control arm and check track 29 - 20 Nm + 90° ♦ replace after each removal

1.2

Removing and installing the track con‐ trol arm

Special tools and workshop equipment required ♦ Extractor -MP 6-425♦ Supporting device -MP 9-200♦ Torque wrench, e.g. -V.A.G 1756-

4 Rep. gr.40 - Front suspension

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 Removing – Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

– Raise the vehicle until the front axle is free of stress.

– Slacken twelve-point nut.

– Raise vehicle and remove wheel.

– Release twelve-point nut.

– Removing noise insulation ⇒ Engine - Mechanics; Rep. gr.

10 Only for vehicles with automatic gearbox: – Insert supporting device -MP 9-200- and support engine/gear‐ box in this position.

For all vehicles: Note

Mark installation position of bolts -1-, otherwise the steering ge‐ ometry must be checked.

Release screws -1-.

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.�

– Push out the drive shaft. To do so position the tool as shown in the fig.

Note

While pushing out the drive shaft make sure there is sufficient clearance.

1. Repairing front wheel suspension

5

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Unscrew screws -3-, if present, at the track control arm.

– Screw out screws -1- and -2-.

– Remove the track control arm.

Only for vehicles with autom. gearbox – Release screws -4- for pendulum support.

– Unscrew screws -5- and -6- for assembly carrier.

Note

Release the screw -1- downwards by slightly pressing the as‐ sembly carrier and take out the wheel-bearing housing.

Install (Valid for vehicles with manual and automatic gearbox).

Remove possible corrosion in the thread/serration of the outer joint.

– Insert track control arm and secure.

– Secure assembly carrier.

– Moisten the serration of the wheel hub with oil.

– Insert outer joint as far as possible into the serration of the wheel hub.

– Screw the steering joint and track control arm with the new screws in the former positions.

– Screw the pendulum support to the gearbox.

– If necessary, screw the coupling rod with the track control arm or with the suspension strut.

– Moisten the contact surface of the twelve-point nut as well as the serration and the thread of the outer joint with oil and screw on new twelve-point nut as far as possible.

– Insert the outer joint into the wheel hub until the outer joint rests in the wheel bearing.

– Install noise insulation ⇒ Engine, Mechanics; Rep. gr. 10 .

– Attach the wheel.

– Lower vehicle, when doing so, ensure that the wheels do not yet touch the ground.

Use new screws!

If the wheel bearings are loaded through the vehicle's own weight, the wheel bearing will be initially damaged. This shortens the life of the wheel bearing.

– Depress brake pedal (assistance of second mechanic re‐ quired).

– Tighten new twelve-point nut to 225 Nm and release by 1/2 a turn.

– Torque wheel hub a further min. 90°.

– Tighten twelve-point nut: Tightening torque: 50 Nm + 60°.

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.�

6 Rep. gr.40 - Front suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Note

The torque wrench is recommended e.g. for tightening the twelvepoint nut -V.A.G 1756- .

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.�

1. Repairing front wheel suspension

7

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tightening torques: Assembly carrier to body ♦ Use new screws!

100 Nm + 90°

Steering joint to track control arm ♦ Use new screws and new lock washer!

20 Nm + 90°

Pendulum support to gearbox ♦ Use new screws!

40 Nm + 90°

Coupling rod to track control arm ♦ Use new screws!

15 Nm + 90°

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.�

8

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.3

Pressing out and in the bearing for the track control arm

Special tools and workshop equipment required ♦ Pressure plate -MP 3-406♦ Pressure plate -MP 3-407♦ Pipe section -MP 3-414♦ Pipe section -MP 3-429♦ Pressure washer -MP 3-456♦ Assembly device -MP 5-402♦ Assembly device -MP 6-401♦ Pressure spindle -MP 6-405♦ Base -MP 6-407♦ Pressure pipe -MP 6-408♦ Workshop press, e.g. -V.A.G 1290 A♦ acid-free lubricant, e.g. -G 294 421Press off front bearing for track control arm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

ŠKODA AUTO A. S. ŠKODA Press in unless frontauthorised bearingby for track control armAUTO 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.�

– Insert bearing into pipe section -MP 3-414- .

Note

Use acid-free lubricant, e.g. -G 294 421- , when pressing in the bearing. Under no circumstances use grease or detergent.

9

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Fitting position of rear bearing for track control arm One of the embossed arrows points to the impression in the track control arm, the kidney-shaped recess (-arrow A-) in the bearing points to the centre of the vehicle.

Pressing out and in the rear bearing for the track control arm Pay attention to the fitting position when pressing in ⇒ page 10 .

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.�

1.4

Removing and installing assembly car‐ rier

Special tools and workshop equipment required ♦ Extractor -MP 6-425♦ Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2Removing – Remove wheel trim caps of the front wheels, for light-alloy wheels remove the caps (pull-off hook in tool kit).

– Raise the vehicle until the front axle is free of stress.

– Slacken left and right twelve-point nut.

– Raise vehicle and remove wheel.

– Unscrew left and right twelve-point nut.

– Remove noise insulation ⇒ Engine - Mechanics; Rep. gr. 10 .

Note

Mark installation position of bolts -1-, otherwise the steering ge‐ ometry must be checked.

10

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Release screws -1-.

– Press out left and right drive shaft. To do so position the tool as shown in the fig.

Note

While pushing out the drive shaft make sure there is sufficient clearance.

– Separate left and right track control arm from steering joint.

– Swivel out the wheel-bearing housing with the steering joint and support.

– Release screwsby-1andAUTO -2-A.and remove support. unless authorised ŠKODA S. ŠKODA AUTOpendulum A. S. does not guarantee or accept any liability Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Release screws for power-steering gear -5-.

– Unscrew nut -7- for coupling rod from anti-roll bar.

– Unscrew screws -6- for exhaust system.

– Position the gearbox jack with adapter, e.g. -V.A.G 1383/Awith -V.A.G. 1359/2- , under the assembly carrier.

– Unscrew screws -3- and -4- for assembly carrier.

– Lower assembly carrier with gearbox jack.

Note

Ensure that the steering gear loosens from the assembly carrier.

– Support steering gear, if necessary clamp with tensioning strap to the top.

Install Before inserting the screws for the assembly carrier, position the steering gear on the assembly carrier and insert the screws for the steering gear.

11

Octavia 1997 ➤ Axles, steering - Edition 11.2011 The threaded bush -1- must fit in the hole of the assembly carrier.

Further installation occurs in reverse order.

Tightening torques ⇒ page 2 .

Once the steering gear has been installed it is then important to check the position of the steering wheel during a test drive.

If the vehicle drifts, a chassis alignment must be performed.

1.5

Pressing out and in rubber-metal bear‐ ing

Special tools and workshop equipment required ♦ Pressure plate -MP 3-407♦ Pressure spindle -MP 3-448♦ Counterholder -MP 6-410♦ Extractor -MP 6-425♦ Assembly 6-430Protected bydevice copyright.-MP 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

♦ Workshop press, e.g. -V.A.G. 1290Awith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ♦ Gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G 1359/2♦ acid-free lubricant, e.g. -G 294 421 A1- .

Pressing out and in the rubber-metal bearings is only possible after removing the assembly carrier.

– Removing and installing assembly carrier ⇒ page 10 .

Pressing out the rubber-metal bearing

12

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Pressing in rubber-metal bearing Note

Coat rubber-metal bearing and assembly carrier with acid-free lubricant before pressing them in, e.g. -G 294 421 A1- . Under no circumstances use grease or detergent.

1.6

Summary of components of the wheel bearing, suspension strut, drive shaft and brake Note

♦ When moving vehicles with drive shaft removed, it is advisable

to install an external joint instead of the drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.

♦ Welding and straightening work is not allowed on the bearing

and wheel control components of the front wheel suspension.

♦ Always replace self-locking nuts. ♦ Always replace corroded self-locking nuts and screws.

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13

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - Self-locking nut, 60 Nm ♦ replace after each removal 2 - Stop 3 - Suspension strut ♦ removing and installing ⇒ page 22 ♦ repairing ⇒ page 27 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 4 - Drive shaft with inner CV joint ♦ removing and installing ⇒ page 32 ♦ repairing ⇒ page 36 5 - Shim 6 - Fillister head screw with in‐ ternal serrations ♦ replace after each removal ♦ initially tighten to 10 Nm and subsequently tighten crosswise to final torque: M8 = 20 Nm + 180° M10 = 50 Nm + 45° ♦ Assignment ⇒ Electronic Catalogue of Original Parts 7 - Drive shaft with inner tripod joint ♦ removing and installing ⇒ page 32 ♦ repairing ⇒ page 48 8 - Fillister head screw with internal serrations ♦ replace after each removal ♦ initially tighten to 10 Nm and subsequently tighten crosswise to final torque: M8 = 20 Nm + 90° M10 = 50 Nm + 45° ♦ Assignment ⇒ Electronic Catalogue of Original Parts 9 - Brake disc (FS-III) ♦ without marking for axial run-out by the copyright.

Copying for private or commercial purposes, in part or in whole, is not permitted ♦ with a fixing Protected hole for wheel hub

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

respect to the Catalogue correctness of information in this document. ♦ Assignment ⇒withElectronic of Original Parts Copyright by ŠKODA AUTO A. S.�

10 - Wheel screw, 120 Nm 11 - Self-locking twelve-point nut ♦ slacken and tighten ⇒ page 4 ♦ replace after each removal 12 - 4 Nm 13 - Brake discs (FS-III) ♦ removing and installing ⇒ Brake systems; Rep. gr. 46

14

Octavia 1997 ➤ Axles, steering - Edition 11.2011 14 - Brake caliper (FS-III) Including for vehicles with engine up to 92 kW. ♦ do not release brake hose when working on the front wheel suspension ♦ tie up with wire or anything similar ♦ repairing ⇒ Brake systems; Rep. gr. 47 15 - Guide bolt (FS-III), 30 Nm ♦ removing and installing ⇒ Brake systems; Rep. gr. 46 16 - Cap (FS-III) 17 - Brake disc (FN 3) ♦ with marking for maximum axial run-out ♦ with 5 fixing holes for the wheel hub ♦ removing and installing ⇒ Brake systems; Rep. gr. 46 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 18 - Wheel hub with pulse rotor for wheel speed sensor ♦ with marking for minimum axial run-out ♦ only on vehicles with ABS ♦ pressing out ⇒ page 17 ♦ installing ⇒ page 17 ♦ Pull off the inner ring of the bearing ⇒ page 17 ♦ Check axial run-out of pulse rotor ⇒ brake systems; Rep. gr. 45 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 19 - Brake discs (FN-3) ♦ removing and installing ⇒ Brake systems; Rep. gr. 46 20 - Retaining spring (FN-3) Protected 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 21unless - Brake carrier (FN-3) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

22 - Brake caliper (FN-3)

Including for vehicles with engine as of 96 kW. ♦ do not release brake hose when working on the front wheel suspension ♦ tie up with wire or anything similar ♦ Removing and installing brake pads ⇒ Brake systems; Rep. gr. 46 ♦ repairing ⇒ Brake systems; Rep. gr. 47 23 - Guide bolt (FN-3), 30 Nm ♦ removing and installing ⇒ Brake systems; Rep. gr. 46 24 - Cap (FN-3) 25 - Screw with securing collar (FN-3), 124 Nm ♦ Clean ribbing on the underside 26 - Wheel-bearing housing Including for vehicles with engine as of 96 kW. ♦ removing and installing ⇒ page 22 ♦ repairing ⇒ page 17 ♦ before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing evenly with -G 052 723 A2-

15

Octavia 1997 ➤ Axles, steering - Edition 11.2011 27 - Cover plate 28 - Self-locking nut, 50 Nm ♦ replace after each removal 29 - Steering joint ♦ check ⇒ page 19 ♦ Inspect rubber bellows for damage, if necessary replace ♦ removing and installing ⇒ page 20 30 - Wheel-bearing housing Including for vehicles with engine up to 92 kW. ♦ removing and installing ⇒ page 22 ♦ repairing ⇒ page 17 ♦ before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing evenly with -G 052 723 A231 - Self-locking nut, 20 Nm + 90° ♦ replace after each removal 32 - Screw ♦ replace after each removal 33 - 8 Nm

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34 - ABS wheel speed sensor ♦ only on vehicles with ABS ♦ insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste) 35 - Self-locking nut ♦ up to 05.98: 50 Nm + 90° ♦ as of 06.98: 60 Nm + 90° ♦ replace after each removal 36 - Track rod with track rod end ♦ removing and installing ⇒ page 22 37 - 10 Nm 38 - Wheel bearing ♦ press out ⇒ page 17 ♦ replace, is damaged when pressing out ♦ installing ⇒ page 17 ♦ The spare part is only delivered as a set „wheel bearing with mounting parts“ (Pos. 11, 39, 38, 28, 31 and 35) 39 - Circlip ♦ pay attention to correct position ⇒ page 17 ♦ replace after each removal 40 - Wheel hub without pulse rotor ♦ only on vehicles without ABS ♦ Assignment ⇒ Electronic Catalogue of Original Parts 41 - Wheel hub with pulse rotor for wheel speed sensor ♦ without marking for minimum axial run-out

16

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ only on vehicles with ABS ♦ press out ⇒ page 17 ♦ installing ⇒ page 17 ♦ Pull off the inner ring of the bearing ⇒ page 17 ♦ Check axial run-out of pulse rotor ⇒ brake systems; Rep. gr. 45 . ♦ Assignment ⇒ Electronic Catalogue of Original Parts

1.7

Repairing wheel bearing housing

Special tools and workshop equipment required ♦ Pressure plate -MP 3-406♦ Pressure plate -MP 3-407♦ Pressure spindle -MP 3-408♦ Pipe section -MP 3-4012♦ Pipe section -MP 3-450♦ Thrust plate -MP 3-467♦ Ring spanner SW 46 -MP 6-413♦ Assembly device -MP 6-414/1♦ Washer -MP 6-415♦ Washer -MP 6-416♦ Thrust piece -MP 6-418♦ Pipe -MP 6-419♦ Pressure pipe -MP 6-420♦ Extractor -MP 6-425♦ Socket wrench insert SW 21 -MP 6-427♦ Spreader -VAS 3424♦ Puller Kukko -V 176♦ Workshop press, e.g. -V.A.G 1290 AProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ♦ authorised Torqueby wrench, e.g.

1756unless ŠKODA AUTO A. S.-V.A.G 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.�

♦ Cross member Kukko 18-0

♦ Grease -G 052 723 A2- (molykote grease) It is only possible to repair the wheel-bearing housing, by pressing out and in the wheel hub and the wheel bearing, after removing the suspension strut and the wheel-bearing housing.

– Remove and install suspension strut and wheel bearing hous‐ ing ⇒ page 22 .

17

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Press the wheel hub out of the wheel bearing

Removing and installing circlip – Remove or replace circlip with commercially available circlip pliers.

Note ♦ Replace. ♦ When inserting, pay attention to the correct position of the cir‐

clip.

Press the wheel bearing out of the wheel bearing housing 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.�

Pull the inner ring of the bearing off the wheel hub – Insert washer -MP 6-416- as shown.

– Screw cross member Kukko 18-0 into washer -MP 6-416- .

– Position thrust plate -MP 3-467- onto wheel hub and pull off the inner ring of the bearing by turning the threaded spindle.

18

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Press the wheel bearing into the wheel bearing housing -A- Wheel bearing – Before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing evenly with -G 052 723 A2- .

Note

After pressing in the wheel bearing, the circlip must be inserted ⇒ page 18 .

Press the wheel hub into the wheel bearing Note ♦ When pressing in the wheel hub, ensure that the washer -MP

6-415- rests against the inner ring of the bearing.

♦ For wheel bearing housing and wheel hub on vehicles includ‐

ing with engine as of 110 kW (brake FN-3) observe the as‐ signment of the wheel hub ⇒ electronic catalogue of original parts .

♦ Wheel hubs with a 3 mm wide ink-jet marking for marking the

minimum axial run-out can also be combined with brake discs without marking of the maximum axial run-out. Then the re‐ duction of the overall axial run-out of the brake FN 3 is not effective.

1.8

Inspecting the steering joint

Inspecting axial play Pull the track control arm down with force and push up again.

Inspecting radial play

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Forcefully push the wheel at the bottom towards the inside and the outside.

Note ♦ For these two tests no play may be felt or be visible. ♦ Observe the steering joint during the tests. ♦ Take into account possible wheel bearing play or „play“ in top

suspension strut bearing.

♦ Inspect rubber bellows for damage, if necessary replace.

19

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.9

Removing and installing the steering joint

Special tools and workshop equipment required ♦ Socket wrench insert SW 19 -MP 6-423♦ Extractor -MP 6-425♦ Socket wrench insert SW 21 -MP 6-427♦ Spreader -VAS 3424♦ Extractor Matra -V176Removing It is only possible to remove the steering joint after removing the suspension strut and the wheel bearing housing.

– Remove and install suspension strut and wheel bearing hous‐ ing ⇒ page 22 .

– Position the special tools as shown in the fig. and slacken the hexagon nut.

-A- Torx screw -T 30-

– Place the extractor as shown in the fig. and push out the steer‐ ing joint.

Install The installation is carried out in the reverse order.

Note

Replace hexagon collar nut.

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.�

20

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tightening torques: Steering joint to wheel-bearing housing 20 Nm + 90°

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.�

21

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.10

Remove and install suspension strut and wheel bearing housing

Special tools and workshop equipment required ♦ Extractor -MP 6-425♦ Socket wrench insert SW 21 -MP 6-427♦ Spreader -VAS 3424♦ Torque wrench, e.g. -V.A.G 1756♦ Extractor Matra -V176Removing – Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

– Raise the vehicle until the front axle is free of stress.

– Slacken twelve-point nut.

– Remove wheel and raise vehicle.

Note

Mark installation position of bolts -1-, otherwise the steering ge‐ ometry must be checked.

– Release screws -1-.

– Push out the drive shaft. To do so position the tool as shown in the fig.

Note

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While pushing out the drive shaft make sure there is sufficient clearance.

22

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Press the track rod off the steering arm using the extractor Matra -V176- (commercially available).

– Disconnect the plug -1- of the ABS wheel speed sensor.

– Remove the ABS wheel speed sensor cable from the ties -arrows-.

– Remove caps -2- and unscrew brake caliper. Secure brake carrier with wire to body.

– Remove the brake disc (the brake disc is secured with a screw to the wheel hub).

– If necessary, unscrew the coupling rod from the suspension strut.

– Unscrew the suspension strut on the body with socket wrench insert -MP 6-427- .

– Take out the suspension strut with the wheel bearing housing.

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.�

23

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Separate the suspension strut from the wheel bearing housing – Insert the spreader -VAS 3424- as shown and spread open the wheel bearing housing.

– Remove the suspension strut.

Install - Remove possible corrosion in the thread/serration of the outer joint.

– Insert the suspension strut with the wheel bearing housing and secure it to the suspension strut dome.

– If necessary, secure the coupling rod to the suspension strut.

– Moisten the serration of the wheel hub with oil.

– Insert outer joint as far as possible into the serration of the wheel hub.

– Screw the steering joint and track control arm with the new screws in the former positions.

– Secure the brake caliper housing to the wheel bearing hous‐ ing.

Note

Tighten the FN-3 brakes at the wheel bearing housing to 124 Nm. – Insert the cable of the ABS wheel speed sensor into the brack‐ ets.

– Mount the plug of the ABS wheel speed sensor.

- Moisten the contact surface of the twelve-point nut as well as the serration and the thread of the outer joint with oil and screw on new twelve-point nut as far as possible.

– Insert the outer joint into the wheel hub until the outer joint rests in the wheel bearing.

– Attach the wheel.

– Lower vehicle, when doing so, ensure that the wheels do not yet touch the ground.

If the wheel bearings are loaded through the vehicle's own weight, the wheel bearing will be initially damaged. This shortens the life of the wheel bearing.

– Depress brake pedal (assistance of second mechanic re‐ quired).

– Tighten new twelve-point nut to 225 Nm and release by 1/2 a turn.

– Torque wheel hub a further min. 90°.

– Tighten twelve-point nut: Tightening torque: 50 Nm + 60° 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.�

24

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Note

A torque wrench is recommended for tightening the twelve-point nut -V.A.G 1756- .

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.�

25

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tightening torques: Suspension strut to suspension strut dome Coupling rod to suspension strut ♦ Use new nuts!

Steering joint to track control arm ♦ Use new nuts!

Brake caliper housing to wheel bearing housing ♦ Use new screws and new lock washer!

26

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.�

60 Nm 90 Nm 20 Nm + 90° 30 Nm

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.11

Repairing the suspension strut

Special tools and workshop equipment required ♦ Socket wrench insert SW 21 -MP 6-427♦ Spring tensioning device, e.g. -S 505 501 V- or -V.A.G 1752/1♦ Suspension strut support, e.g. -V.A.G 1752/2♦ Spring holder with protective lining, e.g. -V.A.G 1752/41 - Shock absorber with spring cap ♦ must be replaced com‐ pletely ♦ Assignment ⇒ Electronic Catalogue of Original Parts ♦ can be replaced individually ♦ Inspecting the shock ab‐ sorber ⇒ page 29 ♦ disposing of ⇒ page 30 2 - Bump stop 3 - Boot 4 - Coil spring ♦ removing ⇒ page 28 ♦ installing ⇒ page 28 ♦ Assignment ⇒ Electronic Catalogue of Original Parts ♦ check colour coding ♦ The surface of the spring coil must not be damaged ♦ replace on both sides of the axle ♦ per axle only use coil springs of the same make 5 - Spring cap 6 - Bush ♦ Only present on vehicles with rough road suspension (PR No. 1GB). This PR No. can be found on the vehicle data sticker in the luggage compartment or in the Service Schedule ⇒ page 166 7 - Axial grooved ball bearing 8 - Suspension strut bearing 9 - Collar nut, 60 Nm ♦ replace after each removal ♦ loosen and tighten

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27

Octavia 1997 ➤ Axles, steering - Edition 11.2011 10 - Spring cap 11 - Collar nut, self-locking, 60 Nm ♦ replace after each removal ⇒ page 28 Removing the coil spring – Clamp the suspension strut support, e.g. -V.A.G 1752/2- , in the vice.

– Clamp the suspension strut to the shock absorber pipe in the suspension strut support.

– Preload the coil spring with spring tensioning device, e.g. V.A.G 1752/1- , until the top spring cap is released.

Removing the coil spring – Pay attention to the correct seating of the coil spring in the adapter, e.g. -V.A.G 1752/4- -arrow-.

Removing the coil spring – Unscrew the collar nut from the piston rod using the socket wrench insert -MP 6-427-, to do so counterhold with Allen key.

– Remove individual parts of the suspension strut and the pre‐ loaded coil spring using the spring tensioning device, e.g. V.A.G 1752/1- -V.A.G 1752/1- .

Installing the coil spring

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 – Position the preloaded coil spring tensioning with respectwith to thespring correctness of information de‐ in this document. Copyright by ŠKODA AUTO A. S.� vice, e.g. -V.A.G 1752/1- , on the bottom spring washer, to do so the spring coil end must lie against the stop -arrow-.

28

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.12

Inspecting the shock absorber

Leaks on the shock absorbers Minor oil leakage (sweating) on the piston rod seal does not entail the replacement of the shock absorber.

If an oil leak is visible (but blunt, dull, possibly dried by dust) and does not propagate any further than from the top shock-absorber plug (piston rod seal) to the bottom spring cap -arrow-, the shock absorber is deemed to be O.K. Note

A slight oil leak is beneficial as the gasket is lubricated and this increases the life time. This applies for shock absorbers on the front as well as the rear axle.

Noises on the shock absorbers Attention must be drawn to the fact that in the event of complaints about noise, the shock absorbers are very often regarded as be‐ ing the source of noise.

Note

In the event of complaints about noises interpreted as knocking or cracking noises, always first perform a test drive with the cus‐ tomer to determine where, when and how these noises occur (preferably on a bumpy dry road).

Inspect shock absorber without gas pressure Defective shock absorbers become noticeable while driving be‐ cause of the knocking noises - caused by wheel hopping - more specifically on poor road and they must be replaced. The failure is mainly caused by the loss of oil. The shock absorber then com‐ pressesProtected and/or expands in jolts. It has an "idle travel" before by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted taking effect. 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.�

Note

Shock absorbers are maintenance-free. It is not possible to top up the shock absorber oil.

Inspect shock absorber with gas pressure Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused by wheel hopping and externally usually exhibit considerable oil leakage.

Manual testing, as described below, can determine if the shock absorber is damaged or not: – Compress the shock absorber by hand.

– While doing so, the piston rod can be moved during the entire stroke time with a uniform resistance and without jerking.

– Release the piston rod. On sufficiently pressurized shock ab‐ sorbers it will automatically return to its original position.

– If this is not the case, the shock absorber need not necessarily be replaced, as it will still operate as a conventional shock ab‐ sorber (see instructions below).

29

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Note ♦ The absorbing function is still fully present without gas pres‐

sure as long as the oil leakage is not too important. However, the noise intensity can deteriorate. On older vehicles it is pos‐ sible to continue using an operational yet pressureless shock absorber without problem.

♦ The spring shock absorbers with gas pressure are only instal‐

led on the rear axle.

♦ The gas pressure in the shock absorber improves the noise

behaviour and the function when driving over poor road sur‐ faces.

1.13

Disposing of the shock absorber

Special tools and workshop equipment required ♦ Pipe cutter, e.g. Stahlwille Express -150/3♦ Protective goggles ♦ Oil catching pan WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Cover the opening during degassing (gas pressure in as-new unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability condition up to 2.5 MPa) and wear inprotective with respect to the correctness of information this document.googles.

Copyright by ŠKODA AUTO A. S.�

Note ♦ Defective shock absorbers with gas pressure are also notice‐

able because of loud knocking noises caused by wheel hop‐ ping and externally usually exhibit considerable oil leakage.

♦ The oils used in the shock absorbers do not contain any harm‐

ful substances. These oils can be disposed of together with drained engine and gearbox oil.

♦ Used oils (this concept refers to used engine and gear oils

including ATF as well as mineral hydraulic oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or thinners, chemicals etc.

♦ After "draining" the used parts must be allowed to drip ade‐

quately.

30

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Drain front shock absorber – Clamp shock absorber in a vice.

– Lever off protective cap with assembly lever or anything similar and remove protective tube.

The protective cap and the protective tube are only present on caulked shock absorbers.

– Position a pipe cutter, e.g. Stahlwille Express -150/3- , and cut through the outer pipe.

– Pull the piston rod upwards and while doing so grip the inner pipe with pipe pliers and press it down in such a way that it remains in the outer pipe when the piston rod is slowly pulled out.

– Pull the piston rod out of the inner pipe.

– Drain shock absorber.

Drain rear shock absorber (shock absorber with gas pressure) – Clamp shock absorber vertically with the piston rod pointing downwards in a vice.

– Drill a hole in the outer pipe ∅ 3 mm -arrow A-.

WARNING

Wear safety goggles.

Note

Gas will escape during drilling of the first pipe wall (only for pres‐ surized shock absorbers).

– Drill further until the inner pipe has also been drilled through (approx. 25 mm deep).

– Drill a second hole (-arrow B-) ∅ 6 mm through the inner pipe.

– Hold the shock absorber over an oil catching pan, move the piston rod several times up and down over its entire stroke until no more oil escapes.

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.�

31

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 Note

The shock absorber can also be opened with a pipe cutter ⇒ page 31 . First the shock absorber must be depressurized by center drilling the outer pipe (-arrow A-) previous fig. ⇒ page 31 .

1.14

Removing and installing a drive shaft

Special tools and workshop equipment required ♦ Extractor -MP 6-425♦ Torque wrench, e.g. -V.A.G 1756Removing Note ♦ The wheel bearing must not be loaded when the twelve-point

nut is loose. At full load the wheel bearing is initially damaged Protected copyright. through the vehicle's own weight, thus shortening the bylife of 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 wheel bearing. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ When moving vehicles with drive shaft removed, it is advisable

to install an external joint instead of the drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.

Assignment of the drive shaft and marking ⇒ electronic catalogue of original parts .

– Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

– Raise the vehicle until the front axle is free of stress.

– Slacken twelve-point nut.

– Remove wheel and raise vehicle.

– Remove noise insulation ⇒ Engine - Mechanics; Rep. gr. 10 .

– Unscrew the drive shaft from the flange shaft/gearbox.

Note

Mark installation position of bolts -1-, otherwise the steering ge‐ ometry must be checked.

32

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Release screws -1-.

– Push out the drive shaft. To do so position the tool as shown in the fig.

Note ♦ While pushing out the drive shaft make sure there is sufficient

clearance.

♦ The drive shaft must not hang down while being pressed out.

Otherwise overstretching will cause damage to the inner joint.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted – Removeunless the drive shaft. 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.�

Note

The following working step must only be performed on vehicles with automatic gearbox.

– Slacken screws of gearbox-pendulum support -arrow- at as‐ sembly carrier.

33

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Lever out the engine/gearbox assembly with a tyre iron in di‐ rection of travel, at the same time the drive shaft with tripod can be removed.

– The -arrow- shows the direction of travel.

Install (vehicles with manual and automatic gearbox) - Remove possible corrosion in the thread/serration of the outer joint.

– Moisten the serration of the wheel hub with oil.

– Insert drive shaft.

– Insert outer joint as far as possible into the serration of the wheel hub.

– Screw the steering joint and track control arm with the new screws in the former positions.

– Screw drive shaft onto flange shaft.

– Screw the pendulum support to the assembly carrier.

- Moisten the contact surface of the twelve-point nut as well as the serration and the thread of the outer joint with oil and screw on new twelve-point nut as far as possible.

– Insert the outer joint into the wheel hub until the outer joint rests in the wheel bearing.

– Install noise insulation ⇒ Engine, Mechanics; Rep. gr. 10 .

– Attach the wheel.

– Lower vehicle, when doing so, ensure that the wheels do not yet touch the ground.

If the wheel bearings are loaded through the vehicle's own weight, the wheel bearing will be initially damaged. This shortens the life of the wheel bearing.

– Depress brake pedal (assistance of second mechanic re‐ quired).

– Tighten new twelve-point nut to 225 Nm and release by 1/2 a turn.

– Torque wheel hub a further min. 90°.

– Tighten twelve-point nut: Tightening torque: 50 Nm + 60°.

Note

The torque wrench is recommended e.g. for tightening the twelvepoint nut -V.A.G 1756- .

34

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.�

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tightening torques: Steering joint to track control arm ♦ Use new screws and new lock washer!

20 Nm + 90°

Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II) Screw M8 x 18 Screw M8 x 48 ♦ Use new screws!

I. 2nd 10 Nm 20 Nm + 90° 10 Nm 20Nm + 180°

Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II) Screw M10 ♦ Use new screws!

Pendulum support to sub-frame ♦ Use new screws!

I. 2nd 10 Nm 50 Nm + 45° 20 Nm + 90°

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.�

35

Octavia 1997 ➤ Axles, steering - Edition 11.2011

2

Repairing drive shaft

Repairing drive shaft with outer and inner CV joint VL 3700 ⇒ page 39 Check outer CV joint ⇒ page 45 Inspecting inner CV joint ⇒ page 46 Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint ⇒ page 48 Disassembling and assembling the tripod joint AAR 2900 ⇒ page 50 Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint ⇒ page 53 Disassembling and assembling the tripod joint AAR 2000 ⇒ page 56 Special tools and workshop equipment required ♦ Circlip pliers, e.g. -VW 161 A♦ Pressure plate -MP 3-406♦ Pressure plate -MP 3-407♦ Pressure spindle -MP 3-448♦ Strutting bushing -MP 6-428♦ Tensioner -MP 6-429♦ Workshop press, e.g. -V.A.G 1290 A♦ Tensioning pliers, e.g. -V.A.G 1682♦ Sealant -D 454 300 A2Note ♦ Assignment of the drive shafts ⇒ Electronic Catalogue of

Original Parts .

♦ Grease joint if necessary, when replacing the joint boot. ♦ Spread the grease mass evenly in the joint boot - only on the

side of the joint.

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.�

36

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - Right joint boot (tubular shaft) ♦ Assignment ⇒ Electronic Catalogue of Original Parts 2 - Fillister head screw with in‐ ternal serrations ♦ replace after each removal ♦ initially tighten to 10 Nm, subsequently tighten cross‐ wise to final torque: M8 x 48 = 20 Nm + 180° M10 x 52 = 50 Nm + 45° ♦ Assignment ⇒ Electronic Catalogue of Original Parts 3 - Shim ♦ Assignment ⇒ Electronic Catalogue of Original Parts 4 - Open warm-type clamp ♦ replace ♦ tensioning ⇒ page 43 5 - Joint boot for inner CV joint, ∅ 94 mm ♦ inspect for tears and chaf‐ ing points ♦ remove from CV joint with drift ♦ The fitting position of the joint boot for the inner CV joint for the right shaft is the same as the fitting position of the joint boot for the outer CV joint ∅ 84mm ⇒ page 44 ♦ before installation coat the inside of the cap with sealant -D 454 300 A2♦ Assignment ⇒ Electronic Catalogue of Original Parts 6 - Joint boot for inner CV joint, ∅ 100 mm ♦ inspect for tears and chafing points ♦ remove from CV joint with drift ♦ Fitting position for the left shaft ⇒ page 42 ♦ Fitting position for the right shaft ⇒ page 43 by copyright.

Copying private or commercial purposes, in part or in whole, is not permitted ♦ before installation coat the inside of theProtected cap with sealant -D for 454 300 A2-

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.� ♦ Assignment ⇒ Electronic Catalogue of Original Parts

7 - Disc spring ♦ Fitting position ⇒ page 42 8 - Inner CV joint ♦ must be replaced completely ♦ pressing out ⇒ page 41 ♦ pressing on ⇒ page 42

2. Repairing drive shaft

37

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ grease ⇒ page 58 ♦ check ⇒ page 46 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 9 - Gasket ♦ The adherend on the inner CV joint must be free of grease and oil! ♦ replace ♦ Remove the protective foil from the gasket and stick it into the inner joint ♦ Assignment ⇒ Electronic Catalogue of Original Parts 10 - Circlip ♦ replace ♦ remove with circlip pliers, e.g. -VW 161 A- , -VW 161 A♦ Assignment ⇒ Electronic Catalogue of Original Parts 11 - Left drive shaft (solid shaft) ♦ Assignment ⇒ Electronic Catalogue of Original Parts 12 - Open warm-type clamp ♦ replace ♦ tensioning ⇒ page 43 13 - Joint boot for outer CV joint ♦ inspect for tears and chafing points ♦ Assignment ⇒ Electronic Catalogue of Original Parts

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

unless authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ♦ pay attention to different version: ∅ 84 mm, ∅ 90bymm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ The fitting position of the joint boot for the outer CV joint ∅ 90 mm for the left shaft ⇒ page 44 ♦ The fitting position of the joint boot for the outer CV joint ∅ 90 mm for the right shaft is determined by the fitting position on the shaft, identical as ⇒ page 44 ♦ The fitting position of the joint boot for the outer CV joint ∅ 84 mm for the left shaft ⇒ page 44 ♦ The fitting position of the joint boot for the outer CV joint ∅ 84 mm for the right shaft ⇒ page 44 14 - Open warm-type clamp ♦ replace ♦ tension with tensioning pliers, e.g. -V.A.G 1682- , ⇒ page 43 15 - Disc spring ♦ Fitting position ⇒ page 42 16 - Thrust ring ♦ Fitting position ⇒ page 42 17 - Circlip ♦ replace ♦ insert into the groove at the shaft 18 - Outer CV joint ♦ must be replaced completely ♦ removing ⇒ page 41 ♦ install: drive onto the shaft with a plastic hammer until the compressed circlip expands ♦ grease ⇒ page 58

38

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ check ⇒ page 45 19 - 22 Nm 20 - M8 = 20 Nm, M10 = 33 Nm 21 - Protective housing

2.1

Repairing drive shaft with outer and in‐ ner CV joint VL 3700

Special tools and workshop equipment required ♦ ⇒ page 36 Note ♦ Assignment ⇒ Electronic Catalogue of Original Parts ♦ Grease joint if necessary, when replacing the joint boot.

1 - Outer CV joint ♦ must be replaced com‐ pletely ♦ removing ⇒ page 41 ♦ install: drive onto the shaft with a plastic hammer until the compressed circlip ex‐ pands ♦ grease ⇒ page 58 ♦ check ⇒ page 45 2 - Circlip ♦ replace ♦ insert into the groove at the shaft 3 - Thrust ring ♦ Fitting position ⇒ page 42

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.�

4 - Disc spring ♦ Fitting position ⇒ page 42 5 - Open warm-type clamp ♦ replace ♦ tension with tensioning pli‐ ers, e.g. -V.A.G 1682- , ⇒ page 43 6 - Joint boot for outer CV joint ♦ Material: Hytrel (Polyelas‐ tomere) ♦ inspect for tears and chaf‐ ing points ♦ Fitting position for the left shaft ⇒ page 45 2. Repairing drive shaft

39

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ Fitting position for the right shaft ⇒ page 45 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 7 - Open warm-type clamp ♦ replace ♦ tensioning ⇒ page 43 8 - Drive shaft ♦ Assignment ⇒ Electronic Catalogue of Original Parts 9 - Joint boot for inner CV joint ♦ Material: Arnitel (Polyelastomere) ♦ inspect for tears and chafing points ♦ Fitting position for the left shaft ⇒ page 44 ♦ Fitting position for the right shaft ⇒ page 44 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 10 - Open warm-type clamp ♦ replace 11 - Cover ♦ remove from CV joint with drift ♦ before installation coat the sealing surface of the cap with sealant -D 454 300 A2♦ The sealing surface must be free of oil and grease!

12 - Inner CV joint ♦ must be replaced completely ♦ pressing out ⇒ page 41 ♦ pressing on ⇒ page 42 ♦ grease ⇒ page 58 ♦ check ⇒ page 46 ♦ Assignment ⇒ Electronic Catalogue of Original Parts 13 - Circlip ♦ replace ♦ remove with circlip pliers, e.g. -VW 161A- , -VW 161A14 - Fillister head screw with internal serrations ♦ replace after each removal ♦ initially tighten toby10 Nm, Copying subsequently toorfinal torque: Protected copyright. for private or tighten commercialcrosswise purposes, in part 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.� M8 x 48 = 20 Nm + 180° M10 x 52 = 50 Nm + 45° ♦ Assignment ⇒ Electronic Catalogue of Original Parts

15 - Shim ♦ Assignment ⇒ Electronic Catalogue of Original Parts 16 - Gasket ♦ The adherend on the inner CV joint must be free of grease and oil! ♦ replace ♦ Remove the protective foil from the gasket and stick it into the inner joint ♦ Assignment ⇒ Electronic Catalogue of Original Parts

40

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 17 - Cover ♦ remove from CV joint with drift ♦ before installation coat the sealing surface of the cap with sealant -D 454 300 A2♦ The sealing surface must be free of oil and grease!

Grease quality and grease quantity Note

The outer joints of the drive shaft are filled with: – Grease for operating at normal temperatures part no.: -G 052 738 A2– Grease from the relevant repair kit – High temperature grease, part no.: -G 052 133 A2- , or part no.: -G 052 133 A3♦ The inner joints of the drive shaft must only be filled with high temperature grease from the relevant repair kit or with grease part no.: -G 052 133 A2- , or part no.: -G 052 133 A3- -G 052 133 A3- ⇒ electronic catalogue of original parts Grease quantity ⇒ page 58 Removing outer CV joint – Drive off joint boot with a drift.

– Drive off the drive shaft with a strong blow of a plastic hammer.

Pressing out the inner CV joint Note

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.�

Support ball hub

2. Repairing drive shaft

41

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Fitting position of the disc spring on the outer joint (gearbox side) -1- Disc spring

Fitting position of the disc spring and thrust ring on the outer joint -1- Disc spring -2- Thrust ring

Pressing in the inner CV joint – Press the joint up to the stop.

– Insert the circlip.

Note

Chamfer on inner diameter of the ball hub (serration) must point towards the bearing collar of the drive shaft.

Fitting position of the joint boot for the inner CV joint ∅ 100 mm on the left shaft Dimension -a- = 17 mm Note

Mark the dimension -a- before installing the joint boot on the drive shaft, e.g. using colour or adhesive tape. Under no circumstances the paintwork must be damaged with a sharp object.

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.�

42

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Fitting position of the joint boot for the inner CV joint ∅ 100 mm on the right shaft The ventilation chamber -A- must be located on the large pipe diameter.

-B- Ventilation hole.

Tighten the open warm-type clamp on the outer joint (at the large diameter) Note ♦ In view of the hard material (as opposed to rubber) of the joint

boot, which requires the use of a stainless steel open warmtype clamp, the latter can only be correctly tightened with tensioning pliers, e.g. -V.A.G 1682- .

♦ Tightening torque: 25 Nm. ♦ Use a torque wrench.

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.�

♦ Make sure the thread of spindle -A- of the tensioning pliers is

smooth. If necessary grease with grease, e.g. molykote MoS2.

♦ If it is not smooth, e.g. if the thread is dirty, the necessary

clamping force of the open warm-type clamp is not reached at the given torque.

– Position the tensioning pliers, e.g. -V.A.G 1682- , as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp.

– Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process).

-A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers Tighten the open warm-type clamp on the outer joint (small di‐ ameter) – Position the tensioning pliers, e.g. -V.A.G 1682- , as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp.

– Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process).

-A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers -C- Torque wrench

2. Repairing drive shaft

43

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tighten the open warm-type clamp on the inner joint – Position the tensioning pliers, e.g. -V.A.G 1682- , as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp.

– Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process).

-A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers -C- Torque wrench Fitting position of the joint boot for the outer CV joint ∅ 90 mm on the left shaft The sealing surface of the joint boot must rest up to the stop on the shoulder of the shaft

Fitting position of the joint boot for the outer CV joint ∅ 84 mm on the left and right shaft On the drive shaft, 1 to 1 1/2 groove must be visible Note

The condition mentioned above regarding the fitting position is also valid for the joint boot for the inner CV joint ∅ 94 mm.

Fitting position of the joint boot for the inner CV joint at the left and right 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.�

44

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Fitting position of the joint boot for the outer CV joint at the left shaft

Fitting position of the joint boot for the outer CV joint at the right shaft

2.2

Inspecting outer CV joint

Disassemble the joint to replace badly soiled grease or if the con‐ tact surfaces of the balls must be inspected for wear and damage.

Removing – With an electric stylus or rubstone mark the position of the ball hub relatively to the ball cage and housing before disassem‐ bling -arrow-.

– Rotate the ball hub and ball cage.

– Remove the balls one after the other.

– Turn the cage until the two rectangular cage windows (-arrow-) rest on the joint part.

– Remove cage with hub.

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.�

2. Repairing drive shaft

45

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Turn the hub segment in the rectangular window of the cage.

– Swivel the hub out of the cage.

Note ♦ The 6 balls of each joint belong to a tolerance group. Inspect

the axle studs, hub, cage and balls for small depressions (pit‐ ting = point erosion) and seizing marks. Load alteration shocks indicate too much torsional clearance in the joint, if this is the case replace the joint. Smoothing and bearing marks do not justify a joint replacement.

♦ Inspect the cage for tears.

Install – Press the required quantity of grease into the joint part.

Grease quality and grease quantity ⇒ page 58 .

– Insert the cage with the hub in the joint part.

Note

The cage must be inserted in the correct position.

– Press in opposite balls one after the other, during this process observe the prior position of the ball hub relatively to the ball cage and to the joint part.

– Insert new circlip in the groove of the shaft.

– Spread any residual grease in the joint boot ⇒ page 58 .

– Installing the joint boot ⇒ page 42 .

2.3

Inspecting inner CV joint

Disassemble the joint to replace badly soiled grease or if the con‐ tact surfaces of the balls must be inspected for wear and damage.

Removing Note

The ball hub and joint part are paired and must be marked before removal. Do not interchange the bearing track assignment.

– Swivel the ball hub with the ball cage.

– Press the ball hub and the ball cage out of the joint part -arrow-.

– Press out the balls from the cage.

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.�

46

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Swivel the ball hub out of the ball cage over the ball bearing track -arrows-.

– Inspect the joint part, ball hub, ball cage and balls for small broken out depressions (pitting = point corrosion) and seizing marks.

Note

Load alteration shocks indicate too much torsional clearance in the joint. If this is the case, replace the joint. Smoothing and bear‐ ing marks do not justify a joint replacement.

Install – Insert the ball hub in the ball cage over the two chamfers. The fitting location is random. Press the balls into the cage.

– Insert the hub with cage upright into the joint part.

Note

When inserting make sure the greatest distance -a- on the joint part is close to the short distance -b- on the hub after it has been swivelled in -arrow-.

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.�

♦ Chamfer on inner diameter of the ball hub (serration) must

point towards the largest diameter of the joint part.

– Swivel in the hub. To do so swivel the hub out of the cage -arrows- until the balls are at bearing track distance.

2. Repairing drive shaft

47

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Lock the hub with the balls into position by exerting consider‐ able pressure on the cage -arrow-.

Inspect the operation of the inner CV joint •

The CV joint is correctly assembled if the ball hub in the joint part can be rolled by hand up and down the entire linear com‐ pensation.

– Push the clamp and the joint boot onto the drive shaft.

– Install drive shaft.

– Press the specified grease quantity for the inner joint into the joint from both sides.

– Spread the prescribed grease quantity evenly into the joint boot.

Grease quality and grease quantity ⇒ page 58 .

– Installing the joint boot ⇒ page 42 .

2.4

Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint

Special tools and workshop equipment required ♦ Pressure plate -MP 3-406♦ Pressure spindle -MP 3-448♦ Pipe section -MP 3-4012-

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.�

♦ Tensioning pliers, e.g. -V.A.G 1275- , -V.A.G 1682♦ Workshop press, e.g. -V.A.G 1290 A♦ Circlip pliers (commercially available) Grease quality and grease quantity Note ♦ The inner joints and the inner tripod joints must only be filled

with high temperature grease from the relevant repair kit ⇒ electronic catalogue of original parts .

♦ Grease quantity for outer CV joint ⇒ page 58 . ♦ Grease quantity for inner tripod joint ⇒ page 58 .

Note ♦ Assignment of the drive shafts ⇒ electronic catalogue of original parts ♦ Grease joint if necessary, when replacing the joint boot. ♦ On tripod joints only apply grease in the joint, never in the grease boot.

48

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - Joint boot for outer CV joint ❑ inspect for tears and chafing points ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 2 - Open warm-type clamp ❑ replace ❑ tensioning ⇒ page 43 3 - Open warm-type clamp ❑ replace ❑ tensioning ⇒ page 43 4 - Drive shaft ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 5 - Joint part ❑ grease ⇒ page 58 ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 6 - Fillister head screw with in‐ ternal serrations ❑ replace after each re‐ moval ❑ initially tighten to 10 Nm, subsequently tighten crosswise to final tor‐ que: M8 x 18 = 20 Nm + 90° M10 x 23 = 50 Nm + 45° ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 7 - Rollers 8 - Tripod spider ❑ Chamfer -arrow- points towards the drive shaft serration 9 - Circlip 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 ❑ replace with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ❑ insert into the groove at the shaft 10 - O-ring seal ❑ no longer necessary for the assembly of the repaired drive shaft 11 - Oblong gasket ring ❑ The gasket ring belongs to the repair set ❑ The gasket ring is not fitted in the series, it is only necessary for the spare parts sector ❑ Assignment ⇒ Electronic Catalogue of Original Parts 12 - Cover ❑ is damaged when removing ❑ is no longer necessary for the assembly of the repaired drive shaft and is therefore only available as a spare part

2. Repairing drive shaft

49

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 13 - Open warm-type clamp ❑ for tripod joint ❑ always replace 14 - Joint boot for tripod joint ❑ inspect for tears and chafing points 15 - Open warm-type clamp ❑ for tripod joint ❑ always replace ❑ tensioning ⇒ page 53 16 - Disc spring ❑ Fitting position ⇒ page 42 17 - Thrust ring ❑ Fitting position ⇒ page 42 18 - Circlip ❑ replace ❑ insert into the groove at the shaft 19 - Outer CV joint ❑ must be replaced completely ❑ removing ⇒ page 41 ❑ install: drive onto the shaft with a plastic hammer until the compressed circlip expands ❑ grease ⇒ page 58 ❑ check ⇒ page 45

2.5

Disassembling and assembling the tri‐ pod joint AAR 2900

Special tools and workshop equipment required ♦ ⇒ page 48 Grease quality and grease quantity ⇒ page 58 Dismantling – Open warm-type clamp on joint part.

– Open the open warm-type clamp at the drive shaft and push back the joint boot.

– Clamp the drive shaft on the joint part in a vice with protective jaws.

– Lever off the cover with a screwdriver -1-.

Note ♦ If the cover cannot be levered off, do likewise on the opposite

side of the cover.

♦ The cover is damaged when levering off, it is no longer nec‐

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted essary for the assembly of theby repaired drive shaft.AUTO A. S. does not guarantee or accept any liability unless authorised ŠKODA AUTO A. S. ŠKODA with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

50

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Remove O-ring seal -arrow- from slot.

– Mark fitting position of parts -1- ... -3- with the help of lines.

-1- Joint part -2- Tripod spider -3- Drive shaft Note ♦ If the parts -1- ... -3- are not marked and if they are not fitted

in their original position again when assembling, at a later stage this could cause noises during driving.

♦ Use a waterproof marker for marking.

– Hold the joint part and remove drive shaft from the vice.

Ensure that the rollers do not topple off the tripod spider and fall onto the floor!

– Hold the drive shaft with the joint part vertically and with the other hand gradually push back the joint part.

– Clamp the drive shaft in a vice with protective jaws.

– Mark the fitting position of the rollers -1- to the tripod spider -2- with a felt-tip pen.

– Remove rollers -1- and place them down on a clean surface.

– Remove circlip.

-1- Circlip pliers (commercially available) – Insert the drive shaft in the press.

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.�

2. Repairing drive shaft

51

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Hold the drive shaft and press out of the tripod spider.

– Remove the joint part along with the joint boot from the drive shaft.

– Clean the drive shaft and the joint part.

Assembling together – Push a small open warm-type clamp for the joint boot onto the drive shaft.

– Insert the joint boot on the drive shaft.

– Insert the joint part on the drive shaft.

Mounting the tripod spider

– Clamp the drive shaft in a vice with protective jaws.

Note

Chamfer -arrow- on the tripod spider must point towards the drive shaft. Chamfer serves as an assembly aid.

– Position the tripod spider on the drive shaft according to the marking and drive in up to the stop.

– Insert new circlip and pay attention to correct position.

– Fit the rollers corresponding to the markings onto the tripod spider.

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 – Remove the drive shaft from the vice. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Slide the joint part over the rollers and hold down.

– Clamp joint part into the vice.

– Insert the oblong gasket ring -A- from the repair set into the groove -arrow-.

Note ♦ Direct sealing occurs between the tripod joint (joint part) and

the joint flange (on the gearbox side) due to the oblong profile shape of the gasket ring.

♦ The cover is no longer necessary.

52

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Press the high temperature grease from the repair set evenly into the tripod joint (on the tripod spider side) -arrow A- and into the rear side of the tripod joint -arrow B-.

Grease quality and grease quantity ⇒ page 58 – Installing the joint boot.

– Tighten open warm-type clamp using pliers.

Tighten open warm-type clamp on the drive shaft side with ten‐ sioning pliers, e.g. -V.A.G 1275- .

– Cover the tripod joint with a cardboard disc -A- and adhesive tape -B-.

Note ♦ Cover the tripod joint after the repair with a self-cut, clean

cardboard disc -A- and adhesive tape -B-. This prevents the tripod spider, the joint part and the grease mass from clogging up with dirt. In addition, this prevents that the tripod joint is inadvertently pushed back when installing the drive shaft.

♦ The adhesive tape and the cardboard disc should be removed

only immediately before screwing the drive shaft together with the joint flange.

2.6

Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint 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 tools to the correctness of information in this document.

Copyright by ŠKODA AUTO A. S.� Special and workshop equipment required

♦ Pressure plate -MP 3-406♦ Pressure plate -MP 3-407♦ Pressure spindle -MP 3-408♦ Spacer sleeves -MP 3-458/2♦ Pressure spindle -MP 6-405♦ Strutting bushing -MP 6-428♦ Tensioner -MP 6-4292. Repairing drive shaft

53

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ Workshop press, e.g. -V.A.G 1290 A♦ Tensioning pliers, e.g. -V.A.G 1275- , -V.A.G 1682♦ Circlip pliers (commercially available) Grease quality and grease quantity Note ♦ The inner joints and the inner tripod joints must only be filled

with high temperature grease from the relevant repair kit ⇒ electronic catalogue of original parts .

♦ Grease quantity for outer CV joint ⇒ page 58 . ♦ Grease quantity for inner tripod joint ⇒ page 58 .

Note ♦ Assignment of the drive shafts ⇒ electronic catalogue of original parts ♦ Grease joint if necessary, when replacing the joint boot. ♦ On tripod joints only apply grease in the joint, never in the grease boot.

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.�

54

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - Joint boot for outer CV joint ❑ inspect for tears and chafing points ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 2 - Open warm-type clamp ❑ replace ❑ tensioning ⇒ page 43 3 - Fillister head screw with in‐ ternal serrations ❑ replace after each re‐ moval ❑ initially tighten to 10 Nm, subsequently tighten crosswise to final tor‐ que: M8 x 28 = 20 Nm + 90° ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 4 - Shim ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts

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.�

5 - Joint part ❑ grease ⇒ page 58 ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 6 - Tripod spider with rollers ❑ Chamfer -arrow- points towards the drive shaft serration 7 - Circlip ❑ replace ❑ insert into the groove at the shaft 8 - O-ring seal ❑ replace 9 - Cover ❑ replace 10 - Open warm-type clamp ❑ for tripod joint ❑ always replace 11 - Joint boot for tripod joint ❑ inspect for tears and chafing points ❑ Assignment ⇒ Electronic Catalogue of Original Parts 12 - Drive shaft ❑ Assignment ⇒ Electronic Catalogue of Original Parts 13 - Open warm-type clamp ❑ replace

2. Repairing drive shaft

55

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ❑ tensioning ⇒ page 43 14 - Disc spring ❑ Fitting position ⇒ page 42 15 - Thrust ring ❑ Fitting position ⇒ page 42 16 - Circlip ❑ replace ❑ insert into the groove at the shaft 17 - Outer CV joint ❑ must be replaced completely ❑ removing ⇒ page 41 ❑ install: drive onto the shaft with a plastic hammer until the compressed circlip expands ❑ grease ⇒ page 58 ❑ check ⇒ page 45 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

2.7

Disassembling and assembling the tri‐ pod joint AAR 2000

Special tools and workshop equipment required ♦ ⇒ page 53 Grease quality and grease quantity ⇒ page 58 Dismantling

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.�

– Open warm-type clamp on joint part.

– Push back the joint boot.

– Straighten the metal tabs -arrows- with a screwdriver and lever off cover.

56

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Remove O-ring seal -arrow- from slot.

– Mark fitting position of parts -1- ... -3- with the help of lines.

-1- Joint part -2- Tripod spider -3- Drive shaft Note ♦ If the parts -1- ... -3- are not marked and if they are not fitted

in their original position again when assembling, at a later stage this could cause noises during driving.

♦ Use a waterproof marker for marking.

– Hold the joint part and remove drive shaft from the vice.

– Clamp the drive shaft in a vice with protective jaws.

– Remove circlip.

-1- Circlip pliers (commercially available)

Protected 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 – Insert the drive shaft in the press.unless with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Hold the drive shaft and push tripod spider off the drive shaft.

– Remove the tripod spider with rollers and lay aside on a clean surface.

– Remove the joint part from the drive shaft.

– Remove the joint boot from the drive shaft.

– Clean the drive shaft and the joint part.

Assembling together – Insert the joint boot on the drive shaft.

– Insert the joint part on the drive shaft.

Install tripod joint Note

Chamfer on the tripod spider must point towards the drive shaft.

Chamfer serves as an assembly aid.

2. Repairing drive shaft

57

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Position the tripod spider on the drive shaft according to the marking and drive in up to the stop.

– Insert new circlip and pay attention to correct position.

– Slide the joint part over the rollers and hold down.

– Remove the drive shaft from the special tool and clamp in the vice.

– Press the high temperature grease from the repair set evenly into the tripod joint (on the tripod spider side) -arrow A- and into the rear side of the tripod joint -arrow B-.

Grease quality and grease quantity ⇒ page 58 – Installing the joint boot.

Note

The bead in the joint boot must fit into the groove of the joint part.

– Remove drive shaft from the vice and clamp the joint part.

– Insert new gasket ring -arrow- from the repair kit in the groove.

– Fit the new cover on the joint part.

Note

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The bores of the cover and joint part must be flush.

– Tighten open warm-type clamp using pliers.

Grease quantity

58

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 Outer joint ∅ mm Total quantity of grease (g) Inner joint ∅ mm Total quantity of grease (g) of which in Spread evenly in the joint Joint (g) Joint boot (g) 1) 81 90 90 45 45 94 (synchronous running) 90 110 120 60 60 100 (synchronous running) 1) 90

110

108 (tripod) 1)

110

110

_

90

110

124 (tripod) 1)

140

140

_

98

130

100 (synchronous running) 2)

190

190

_

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59

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1) Valid for all vehicles, except 1.9 ltr./74 kW PD and 1.9 ltr./96

kW PD engines.

2) Valid for vehicles with 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD

engines.

Grease quality - outer CV joint The outer CV joints can be filled with the following grease quali‐ ties: ♦ Grease for operating at normal temperatures, part no.: -G 052 738 A2♦ Grease from the relevant repair kit ♦ High temperature grease, part no.: -G 052 133 A2- , or part no.: -G 052 133 A3Grease quality - inner CV joint The inner CV joints can be filled with the following grease quali‐ ties: ♦ Grease from the relevant repair kit ♦ High temperature grease, part no.: -G 052 133 A2- , or part no.: -G 052 133 A3Note

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.�

♦ -G 052 133 A2- Can with a grease quantity of 90 g ♦ -G 052 133 A3- Can with a grease quantity of 120 g ♦ Grease joint if necessary, when replacing the joint boot. ♦ Spread the quantity of grease for the joint evenly in the joint

on the left and right.

♦ Spread the quantity of grease for the joint boot evenly in the

joint boot - only on the side of the joint.

60

Octavia 1997 ➤ Axles, steering - Edition 11.2011

42 –

Rear suspension

1

Repairing rear axle - drum brake

Removing and installing rear axle ⇒ page 61 Summary of components of rear axle ⇒ page 63 Replace the rubber-metal bearing ⇒ page 67 Removing and installing shock absorber/spring ⇒ page 82 Disassembling and assembling shock absorber ⇒ page 83

1.1

Removing and installing rear suspen‐ sion

Special tools and workshop equipment required ♦ Tester for brake-power regulator, e.g. -V.A.G 1310♦ Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2♦ Brake filling and bleeding device, e.g. -VAS 5234♦ Remove plugs for brake line ♦ Brake fluid ⇒ Brake systems; Rep. gr. 00 ♦ Assembly paste -G 052 150 A2Removing – Remove wheels.

– Release the hand-brake.

Note

Do not slacken the mounting bracket on body for the removal of the rear axle, otherwise the overall track of the rear axle must be checked, adjusted if necessary.

– Remove the screws -1- while the vehicle is standing on its wheels. To do so, raise the vehicle if necessary until the screws can be reached.

– Raise the vehicle to the height required for installation in order to relieve tension from coil spring.

– Tilt the rear centre console, if necessary remove ⇒ Body Work; Rep. gr. 68

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.�

1. Repairing rear axle - drum brake

61

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Release adjusting nut -arrow-.

– Remove the hand-brake cables -1- from the hand-brake lever.

– Pull hand-brake cables out of guide tubes.

– Unclip brake cables -arrows-.

– Detach retaining clips -2- from brake hose fixture.

– Separate brake lines.

Note

Seal lines with plugs.

– Unplug connectors from the wheel speed sensors.

– Unclip the wheel speed sensor cable from the bracket.

Only on vehicles fitted with brake-power regulator (vehicles with‐ out ABS): – Unscrew bolt -1- of the brake-power regulator.

Valid for all vehicles: – Support the rear axle with gearbox jack with adapter, e.g. V.A.G 1383A- with -V.A.G 1359/2- .

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.�

62 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Unscrew bolt -1- of the brake-power regulator.

Install – Before inserting the rear axle, grease the kidney-shaped cav‐ ities of the rubber-metal bearings with assembly paste -G 052 150 A2- .

The installation is carried out in the reverse order.

Note ♦ When tightening the screw of the rubber-metal bearing, the

axle body must be in the horizontal position (unladen condi‐ tion).

♦ When installing the hand brake cables, pay attention to the

correct fitting position ⇒ Brake systems; Rep. gr. 46 .

– Bleeding brake system ⇒ Brake systems; Rep. gr. 47 .

– If fitted, inspect the load-sensitive brake pressure regulator and set if necessary ⇒ Brake systems; Rep. gr. 47 .

Once the steering gear has been installed it is then important to check the position of the steering wheel during a test drive.

If the vehicle drifts, a chassis alignment must be performed.

Note

After slackening or changing the mounting bracket, check the overall track of the rear axle, adjust if necessary.

Tightening torques: Shock absorber to body ♦ Use new screws!

30 Nm + 90°

Rear suspension to bearing bracket Pipe screws, screws to brake lines

45 Nm + 90° 14 Nm

1.2

Summary of components of rear axle Note

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♦ Welding and straightening on axle body and axle studs not allowed. ♦ Always replace the self-locking screws and nuts. ♦ Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.

1. Repairing rear axle - drum brake

63

Octavia 1997 ➤ Axles, steering - Edition 11.2011 1 - Wheel screw, 120 Nm 2 - 4 Nm 3 - Brake disc ♦ reset brake before remov‐ ing the brake drum 4 - Cap ♦ replace after each removal ♦ press off ⇒ page 108 ♦ inserting ⇒ page 109 5 - Self-locking twelve-point nut 70 Nm +40° ♦ replace after each removal 6 - Wheel hub with wheel bear‐ ing and pulse rotor ♦ only on vehicles with ABS ♦ The wheel bearing and the wheel hub are fitted togeth‐ er in one housing ♦ this component is mainte‐ nance-free and requires no clearance adjustment; ad‐ justment as well as repair work are not possible ♦ removing and installing ⇒ page 106 7 - Wheel hub with wheel bear‐ ing without pulse rotor ♦ only on vehicles without 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 ABS with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ The wheel bearing and the wheel hub are fitted together in one housing

♦ this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair work are not possible ♦ removing and installing ⇒ page 106 ♦ must be replaced completely 8 - 50 Nm + 60° ♦ replace after each removal 9 - Brake carrier with brake shoe 10 - Holder for hand-brake cable ♦ replace 11 - Hand-brake cable 12 - Self-locking nut ♦ replace after each removal 13 - Self-locking screw, 30 Nm + 90° ♦ replace after each removal ♦ if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying attention to the fitting instructions of the manufacturer ♦ the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side

64 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 14 - 45 Nm + 90° ♦ replace after each removal ♦ insert from the outside of the vehicle ♦ when tightening the screw, the axle body must be in the horizontal position (unladen condition) 15 - Mount for rear axle ♦ check the overall track of the rear axle after installation and adjust if necessary ♦ avoid slackening in order to remove the rear axle 16 - Holder for hand-brake cable 17 - Rubber-metal bearing ♦ removing and installing ⇒ page 67 18 - Socket nut 19 - Brake-power regulator ♦ only on vehicles without ABS ♦ testing and adjusting ⇒ Brake systems; Rep. gr. 47 20 - 20 Nm 21 - 16 Nm 22 - 20 Nm + 45° ♦ replace after each removal 23 - Balancing weight 24 - Axle body ♦ The locating face and the threaded holes for axle studs must be free from enamel and dirt 25 - ABS wheel speed sensor ♦ only on vehicles with ABS 26 - 8 Nm 27 - bottom base

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28 - Coil spring ♦ removing and installing ⇒ page 82 ♦ check for paint damage, if necessary eliminate paint damage ♦ Assignment ⇒ Electronic Catalogue of Original Parts ♦ only use helical springs of the same make on the rear axle 29 - top base ♦ installing ⇒ page 82 30 - 40 Nm + 90° ♦ replace after each removal ♦ insert from the inside of the vehicle ♦ when tightening, take the installation angle of the rear axle to the shock absorber into account ⇒ page 66 ♦ While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and tighten the screw 31 - Self-locking screw, 30 Nm + 90° ♦ replace after each removal

1. Repairing rear axle - drum brake

65

Octavia 1997 ➤ Axles, steering - Edition 11.2011 ♦ if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying attention to the notes of the manufacturer ♦ the rework of the thread for the weld nut is permissible on maximum 1 screw point per vehicle side 32 - Shock absorber ♦ can be replaced individually ♦ removing and installing ⇒ page 82 ♦ Assignment ⇒ Electronic Catalogue of Original Parts ♦ disposing of ⇒ page 30 ♦ Inspecting the shock absorber ⇒ page 29 ♦ only use helical springs of the same make on the rear axle Note

Shock absorbers are not to be re‐ paired.

33 - Self-locking nut ♦ replace after each removal 34 - Brake line 35 - Axle stud ♦ Straightening work is not allowed! ♦ Re-cutting the thread is not allowed 36 - Protection against stones 37 - Fixing element for protection against stones ♦ Protection against stones included in the scope of delivery Installation angle of rear axle/shock absorber 1 - Shock absorber 2 - track control arm α - approx. 104°

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66 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.3

Replacing the rubber-metal bearing

1.3.1

Replacing the rubber-metal bearing version 1

Special tools and workshop equipment required ♦ Assembly device -MP5-400/1♦ Assembly device -MP5-400/2♦ Assembly device -MP5-400/3♦ Assembly device (screw) -MP5-401/2♦ Assembly device (nut) -MP5-401/3♦ Assembly device (bearing) -MP5-402♦ Pipe -T10263/6♦ Engine/gearbox jack with adapter , e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing: – Raise vehicle and remove rear wheels.

– Unscrew screws of front wheelhouse liners on both vehicle sides ⇒ Body Work; Rep. gr. 66 .

– Unhook handbrake cable from the holders -arrows- (on both vehicle sides).

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– Release the clamps -arrow A- for attaching the brake lines from the brake line holders (on both vehicle sides).

1. Repairing rear axle - drum brake

67

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Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Remove the screw -1- from the brake line holder on the right vehicle side.

– Unhook the brake lines from the line holders. Do not separate the brake lines.

Vehicles with ABS – Unhook the ABS line from the clips.

Vehicles fitted with load-sensitive brake pressure regulator (ve‐ hicles without ABS) – Release screw -1-.

Continued for all vehicles

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.�

– Insert wooden block -A- into the adapter, e.g. -V.A.G 1359/2- .

– Support the axle with engine/gearbox jack with adapter.

Vehicles with fixing screws mounted on the outside

– Unscrew the nuts of the fixing screws -1- from the axle.

– Remove fixing screws -1- from the axle.

Vehicles with fixing screws mounted on the inside

68 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Remove the screws -2- of the bearing bracket for the axle on the right vehicle side from the body.

Note

Before removing the screws of the bearing brackets for the axle, mark the position of the bearing bracket on the body.

– Remove the fixing screw -1- for the axle on the left vehicle side from the bearing bracket for the axle.

– Slightly lower the rear axle out of the bearing brackets so that the brake line is not damaged.

– Remove the fixing screw -1- for the axle on the right vehicle side from the bearing bracket for the axle.

– Remove the bearing bracket from the axle.

Continued for all vehicles – Secure axle e.g with wire to body.

– Position assembly devices, as shown, and pull the rubbermetal bearing -1- out of the axle body -2-.

Note ♦ The pipe -T10263/6- must be installed on the rubber-metal

bearing in such a way that the contact surface of the pipe -1rests evenly against the rubber-metal bearing.

♦ Cut off the rubber edge in the contact point e.g with a sharp

knife so that the pipe cutout -arrow- rests fully on the plastic shoulder/rubber-metal bearing.

♦ When pulling out the rubber-metal bearing, the plastic shoul‐

der/rubber-metal bearing breaks off. In case of breakage, a Protected Copying for private or commercial purposes, in part or in whole, is not permitted loud crack can bybecopyright. heard. 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.�

– Pull out rubber-metal bearing by turning the assembly device (nut) -MP5-401/3- .

– Counterhold the assembly devices by hand when completing the pull-out process.

– Remove assembly devices and unscrew assembly device (nut) -MP5-401/3- .

1. Repairing rear axle - drum brake

69

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Clamp the pipe -T10263/6- in the vice, as shown in the fig.

– Remove the rubber-metal bearing from the pipe -T10263/6- , for example using a screwdriver, drive out with a hammer if necessary.

Installing:

– Fasten rubber-metal bearing -1- with assembly devices and nut -2- and insert into the axle body -3-.

– Pay attention to the correct fitting position of the rubber-metal 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. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Fitting position of the rubber-metal bearing – Align orientation nubs -1- or orientation bead -2- to edge of track control arm -3- -arrow-.

70 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Insert the rubber-metal bearing -1- by turning the nut -MP 5-401/3- up to the stop in the axle body -2-.

– Check the fitting position of the rubber-metal bearing.

– Grease the kidney-shaped cavities of the rubber-metal bear‐ ing with assembly paste -G052 150 A2- .

Vehicles with fixing screws mounted on the outside – Carefully raise the rear axle so that the rubber-metal bearing engages in the bearing brackets for the axle.

– Insert the new fixing screws -1- into the bearing brackets for the axle.

– Screw new nuts onto the fixing screws -1- for bearing brackets of the rear axle and tighten.

Vehicles with fixing screws mounted on the inside – Position the bearing bracket for the axle on the right vehicle side on the rubber-metal 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. S. does not guarantee or accept any liability Insert awithnew fixing -1from thein inside intoCopyright the bearing respect to the screw correctness of information this document. by ŠKODA AUTO A. S.�

bracket for the axle on the right vehicle side.

– Carefully raise the rear axle so that the rubber-metal bearing engages on the left vehicle side in the bearing bracket for the axle.

– Ensure that the bearing bracket for the axle on the right vehicle side rests at the same time against the body in the marked position.

– Screw the new fixing screws -2- of the bearing bracket for the axle on the right vehicle side into the body and tighten.

Continued for all vehicles Note

When tightening the rubber-metal bearing screws and nuts, the axle body must be in the unladen condition (unladen weight po‐ sition).

Vehicles with ABS – Hook on the ABS line in the clips.

Vehicles fitted with load-sensitive brake pressure regulator (ve‐ hicles without ABS)

1. Repairing rear axle - drum brake

71

Octavia 1997 ➤ Axles, steering - Edition 11.2011 – Screw in the screw -1-.

– Inspecting or adjusting the brake-power regulator ⇒ Brake systems; Rep. gr. 47 .

Continued for all vehicles

– Install the screw -1- for the brake line holder on the right vehicle side.

– Hook on the brake lines in the line holders.

– Push clamps -arrow A - into the brake hose fixtures (on both vehicle sides).

Note

When installing the hand brake cables, pay attention to the correct fitting position ⇒ Brake systems; Rep. gr. 46 .

– Hook hand brake cables into the holders -arrows- (on both vehicle sides).

– Screw in screws of front wheelhouse liners on both vehicle sides ⇒ Body Work; Rep. gr. 66 .

– Attach the wheels.

– Perform chassis alignment ⇒ page 167 .

– Perform a test drive.

– Check the steering wheel position during the test drive.

Caution

If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform a chassis alignment ⇒ page 167 .

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.�

72 Rep. gr.42 - Rear suspension

Octavia 1997 ➤ Axles, steering - Edition 11.2011 Tightening torque: Rear axle to bearing bracket for axle ♦ Use new screws and nuts!

45 Nm + 90°

♦ Tighten in unladen weight position Bracket of rear axle to structure ♦ Use new screws!

30 Nm + 90°

♦ Install in the marked position Brake line holder to vehicle body Screw for brake-power regulator

16 Nm 16 Nm

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.�

73

Octavia 1997 ➤ Axles, steering - Edition 11.2011

1.3.2

Replacing the rubber-metal bearing version 2

Special tools and workshop equipment required ♦ Assembly device -MP5-400/1♦ Assembly device -MP5-400/2♦ Assembly device -MP5-400/3♦ Assembly device (nut) -T10254/4♦ Assembly device (screw) -T10254/5♦ Pipe -T10263/6♦ Hydraulic cylinder -VAS 6178♦ Foot pump -VAS 6179♦ Engine/gearbox jack with adapter , e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing: – Raise vehicle and remove rear wheels.

– Unscrew screws of front wheelhouse liners on both vehicle sides ⇒ Body Work; Rep. gr. 66 .

– Unhook handbrake cable from the holders -arrows- (on both vehicle sides).

– Release the clamps -arrow A- for attaching the brake lines Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted from the brake line holders (on both sides). unless authorised by ŠKODA AUTO vehicle 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.�

74

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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DOWNLOAD THE COMPLETE MANUAL