Skoda Workshop Service and Repair Manuals

Disassembling and assembling the output shaft (input shaft) Special tools and workshop equipment required t  Pressure plate -MP 3-411- t  Inertia extraction attachment (for inertia extractor MP 9-501) -MP 3-507- t  Impact mandrel for roller bearing -MP 3-513- t  Extractor -MP 3-520- t  Inertia extractor -MP 9-501-

t	When installing new pinions or a new output shaft observe the technical data → Chapter.

t	Insert all bearings, gears and synchronizer rings in the gearbox with gear oil.

t	Do not interchange the synchronizer rings. If re-used always assign to the original gear.

1 -	Nut, 60 Nm

q	always replace

2 -	Disc spring

q	Fitting position: curved side points to gearbox housing cover

3 -	Supporting ring

4 -

Spring

q	Fitting position → Fig.

5 -	5th gear sliding sleeve

q	removing and installing → Fig. and → Fig.

6 -	5th gear synchronizer body

q	removing and installing → Fig. and → Fig.

7 -	Arresters (3 pieces)

q	Fitting position → Fig.

8 -	5th gear synchronizer ring

q	check for wear → Fig.

9 -	5th gear sliding gear

10 -	Needle bearing

11 -	Bushing for needle bearing

q	Fitting position: The oil pockets -arrow- point towards the 5th gear synchronizer body.

12 -	Gearbox housing

13 -	Grooved ball bearing

q	remove → Fig.

q	pressing on → Fig.

14 -	4th gear sliding gear

15 -

Circlip

q

replace

16 -	4th gear synchronizer ring

q	check for wear → Fig.

17 -

Spring

18 -	Sliding sleeve 3rd and 4th gear

19 -	Synchronizer body for 3rd and 4th gear

20 -	Arresters for synchronizer body (3 pieces)

21 -	Sliding sleeve with 3rd and 4th gear synchronizer body

q	Assembling the sliding sleeve with synchronizer body → Fig. and → Fig.

q	Fitting position of the sliding sleeve with synchronizer body → Fig.

22 -	3rd gear synchronizer ring

q	check for wear → Fig.

23 -	3rd gear sliding gear

24 -

Washer

q	holds the thrust washers → Item in the correct position on the output shaft

25 -	2nd and 3rd gear thrust washers

26 -	2nd gear sliding gear

27 -	2nd gear synchronizer ring

q	check for wear → Fig.

28 -	Sliding sleeve with 1st and 2nd gear synchronizer body

q	Assembling the sliding sleeve with synchronizer body → Fig. and → Fig.

29 -	1st gear synchronizer ring

q	check for wear → Fig.

30 -	1st gear sliding gear

31 -	Output shaft

q	is paired with the gear pinion of the final drive, always replace together

32 -	Cylindrical-roller bearing

q	removing → Fig.

q	pressing on → Fig.

q	Fitting position: the marking on the bearing points upwards

33 -

Supports

q	for oil supply

34 -

Washer

35 -

10 Nm

36 -	Clutch housing

Pull off grooved ball bearing with 4th gear sliding gear –  Carefully secure output shaft with protective jaws -A- in the vice.

Press on grooved ball bearing Fitting position: Groove of circlip points towards nut thread.

Disassembling and assembling the sliding sleeve and 3rd, 4th and 5th gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arresters for synchronizer body –  Slide the sliding sleeve over the synchronizer body. The recesses for the arresters on the synchronizer body and the sliding sleeve must be positioned above one another.

Assembling the sliding sleeve and 3rd, 4th and 5th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and install springs with 120° offset. The angled extremity of the spring must catch in the hole of the synchronizer body -arrow-.

Fitting position of the sliding sleeve/3rd and 4th gear synchronizer body The wider collar of the synchronizer body -arrow- points towards the 4th gear.

Disassembling and assembling the sliding sleeve and 1st and 2nd gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arrester –  Slide the sliding sleeve over the synchronizer body. The recesses for the arresters on the synchronizer body and the sliding sleeve must match.

Assembly of the sliding sleeve/1st and 2nd gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and mount springs with 120° offset. The angled extremity of the spring must catch in the hole of the synchronizer body -arrow-.

Check 1st gear through 5th gear synchronizer ring for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance “a” with a feeler gauge.

	Fitting dimension	Wear limit
Clearance “a”	1,2 to 1,8 mm	0,5 mm

Pull out the cylindrical-roller bearing from the clutch housing –  Insert inertia extraction attachment -MP 3-507- in the cylindrical-roller bearing and turn. –  Pull out bearing with inertia extractor -MP 9-501 -.

Drive in the cylindrical-roller bearing into the clutch housing