I decided to write this guide to help anyone wanting to change their gearbox oil, but also included is how to check the gearbox oil level, and replacing the gearbox gear selector shaft oil seal.

I wrote this guide after changing the gearbox oil, and replacing the gearbox gear selector shaft oil seal, on my 1999 1.3mpi felicia (right hand drive), but I believe that it is a very similer procedure on all Felicias and Favorits.

It's not too hard a job, and for anyone who has changed their engine oil, it's not much different. Also I will be using a lot of information I gathered together in this topic http://www.briskoda.net/forums/topic/309866-gear-selector-linkage-gaiter/

Approximately 2.4 liters of gear oil is needed to fill the transmission

I also recommend using a pair of non-permeable gloves.

 

To check gearbox oil level skip straight to step 10

For just changing gearbox oil follow steps 1,2 then skip to 10 onwards

Replacement of the oil seal is possable without changing the gearbox oil, but expect some oil loss.

Drainage of the oil is better when warm, after a short journey (but I didn't bother and found it not too necessary)

 

Step 1: Safely gain access to the underside of the vehicle.

 

2: The gearbox drain plug is situated below the left hand driveshaft (looking from drivers seat), on the side of the gearbox (shown half unscrewed in photo).Clean the area around the gearbox drain plug and use a 19mm socket or spanner, to loosen the plug. Then place a suitable container below the plug, and unscrew it by hand, keeping it pressed in until the final thread, then pull it away sharply to stop the oil running down your arm. Also watch out for oil splashing in eyes as it drains.

 

(If just changing the oil skip down to step 9)

 

3: For replacing the selector shaft oil seal, the shaft will look like either of these photos (1st photo pre 1996, 2nd post 1996) A different universal joint may be used aswell. 

Start by removing the retaining clip over the spring/roll pin.

 

 

 

 

 

4: Then drift out the spring/roll pin (it may be necessary to rotate the shaft slightly to aid removal), and then disconnect the joint from the selector shaft.I tied the linkage up to stop any strain on the gearstick end of the linkage.

 

 

 

5: Remove the gaiter (if applicable) then prise out the old seal using a suitable flat bladed impliment or long needle nosed pliers (I found a wood chisel very useful) And remove the seal over the end of the shaft. Watch out for oil spillage when seal is removed.

 

6: Clean the seal housing, and check the shaft for sharp burrs or deep scratches and polish out if necessary.

 

 

 

7:  Tape over the end of the shaft and the spring pin hole. Then apply a dab of grease to the edges and sealing lip of a new seal, part number : 002301227 (pre 1996 seal for use with gaiter) 002301227B (post 1996 flush fitting seal)

Then press the seal in squarely, using a sutable deep socket that rests on the seals outer lip, and fits over the selector shaft. Or I used a bolt that fit over the selector shaft that rested squarely on the seal's lip, I suppose a washer would also work, then a length of 22mm copper pipe,and then used a hammer to drive it in. (pre 1996 seal in photo below)

 

 

8: Refit the gear selector shaft gaiter if applicable, and follow steps 4 and 3 in reverse to refit the likage to the selector shaft, using a new spring pin, part number N10439701 and new retaining clip if necessary. Don't forget to put the clip on before reconnecting the shaft to the linkage, and to remove anything used to support the linkage.

 

(Back to the gearbox oil change)

 

9: Clean the drain plug and the plug threads, plus the threads in the gearbox. Fit a new sealing washer to the plug, part number N0138272, then refit the plug tighting it to to the correct torque if possable. I did 37Nm or 27lbf ft

 

10: To Refill and/or to check the gearbox oil level, the spedometer drive unit (pictured below) needs to be removed  Also to check the oil level the car needs to be level and not to have been driven for at least 5 mins.

 

 

11: To remove the speedometer unit, clean the area around the unit and remove the 9mm bolt securing the retaining plate in place. Slide the retaining plate to the right (again looking from drivers view) it may be tight and may need some persuasion. Clean the area again being very carefull this time. Then withdraw the speedometer unit from the gearbox in a upward movment (again it might be tight) The drivegear may come out with the unit or my remain in place meshed with the diff gear (depending on type of speedo unit used) Be very CAREFUL that the drive gear does not drop into the gearbox.

 

12: The oil level is checked by measuring the hight of the oil on the drivegear, using it like a dipstick. The oil level should be at least 4mm up from the bottom drivegear. 

 

13 Refilling or toping up is done slowly through the speedometer drivegear unit's appature.

 

 

 

14:With the oil level correct, check the sealing ring on the speedometer unit for deterioration and replace if necessary. Refitting of the speedometer unit is done by reversing step 11. Making sure that the drivegear correctly meshes with the diff gear and that the recessed lugs in the side of the speedometer unit, are parallel with the line of the driveshafts, so the retaining plate can correctly locate and hold the unit in place.

 

15: Get yourself a cup of tea, a pint of beer, or whatever your posion is because that is the job done.

 

 

If your car has air con you will need to undo the speedo drive from under car as air con heater box covers your easy access to this and you need to add some hose on the end off a funnel to fill gear box back up... bet theres not many around with air con...

Saw this made up by bowders1 (credit due there) http://s257.photobucket.com/user/Bowders1_2008/media/VRS%20Maintainance/VRS%20Replace%20Gearbox%20Oil/2013-05-18111921_zpsbc186244.jpg.html

Could make something up like this if struggling for room to fill up gearbox, it's something like what uma1998 describes.

what if the "drive gear" had fallen in de gearbox? This might be the case I came in. Greetings, jawi

You have to remove the gearbox.

problem already solved

but thanks for the tip

the allenscrew in the centre left of the toppicture , what use does this have?

I can't find anything about in Haynes

Edited 20 January, 20188 yr by jawi

On 1/20/2018 at 23:03, jawi said:

the allenscrew in the centre left of the toppicture , what use does this have?

That is a screw that holds a very important part inside gearbox. It is the part that springs back the gear shifter to neutral position.

okidoki, thanks, I will stay away from it

Hi AlI 

I have just done the shifter shaft seal on my 94 Favorit but I am having huge trouble getting the new spring pin in. Any tips or suggestions.  Just can't seem to align, hold the pin and hit hard enough with the hammer all at same time

Cheers

My gear selector shaft seal has started to leak again. So that's about 40,000 miles / 8 years that it has lasted, and that is with the protective gaiter.

 

Also this might be a bit late for wesacosa, but a pair of waterpump / alligator pliers can help getting the pin in.