Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft Special tools and workshop equipment required t  Bushing -MP1-316 (30-100)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-408 (VW 412)- t  Pipe section -MP3-414 (VW 516)- t  Thrust piece -MP3-423 (VW 407)- t  Pressure plate -MP3-431 (3002)- t  Pipe section -MP3-450 (VW 415A)- t  Pipe section -MP3-451 (VW 422)- t  Distance sleeve -MP3-458/2 (VW 472/2)- t  Flywheel type belt pulley fitting tool -MP9-400- t  Pressure plate -T10080- t  Pressure plate -T10081- t  Insert base -T10083- t  Pressure plate -T10084A- t  Cap -T30066 (30-23)- t  Separating device 12...75 mm, e.g. -Kukko 17/1- t  Extractor, e.g. -Kukko 18/1- t  Interior extractor 30...37 mm, e.g. -Kukko 21/5- t  Countersupport, e.g. -Kukko 22/1 -   Note t  When installing new pinions 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 sliding gear. t  On certain gearboxes the needle bearing for the 4th gear sliding gear is additionally installed with a bushing Pos. 25 The circlips Pos. 13 and Pos. 15 are installed on certain gearboxes. Assign components via → Electronic Catalogue of Original Parts.

1 -

Circlip

q	always replace → Electronic Catalogue of Original Parts

q	Determine thickness → Chapter

2 -	Sliding sleeve with 5th gear synchronizer body

q	removing and installing → Chapter

q	disassembling → Fig.

q	Assembling sliding sleeve with 5th gear synchronizer body → Fig. and → Fig.

3 -	5th gear synchronizer ring

q	check for wear → Fig.

4 -	5th gear sliding gear

5 -	Needle bearing

q	for 5th gear

q	replace together with bushing Pos. 6

q	Assignment → Electronic Catalogue of Original Parts

6 -

Bushing

q	for 5th gear needle bearing

q	replace together with needle bearing Pos. 5

q	press off with bearing support for grooved ball bearing → Fig.

q	pressing on → Fig.

q	Assignment → Electronic Catalogue of Original Parts

7 -	Gearbox housing

8 -	Bearing support for grooved ball bearing

q	If the bearing support is released from the gearbox housing, it must always be replaced

q	Only replace grooved ball bearing together with the bearing support → Electronic Catalogue of Original Parts

q	pressing off → Fig.

q	pressing on → Fig.

9 -	Drive shaft

10 -	Needle bearing

q	for 3rd gear

11 -	3rd gear sliding gear

12 -	3rd gear synchronizer ring

q	check for wear → Fig.

13 -

Circlip

q	installed on certain gearboxes, assign via → Electronic Catalogue of Original Parts

q	pushing out → Fig.

q	inserting → Fig.

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

q	press off with 3rd gear sliding gear → Fig.

q	disassembling → Fig.

q	Fitting position sliding sleeve/synchronizer body → Fig.

q	Assemble sliding sleeve/synchronizer body → Fig. and → Fig.

q	pressing on → Fig.

15 -

Circlip

q	installed on certain gearboxes, assign via → Electronic Catalogue of Original Parts

q	pushing out → Fig.

q	inserting → Fig.

16 -	4th gear synchronizer ring

q	check for wear → Fig.

17 -	4th gear sliding gear

18 -	Needle bearing

q	for 4th gear

q	on certain gearboxes a needle bearing Pos. 24 is installed together with a bushing Pos. 25, assign via → Electronic Catalogue of Original Parts

19 -	Thrust washer

20 -	Inner ring

q	for cylindrical-roller bearing

q	press off with 4th gear sliding gear → Fig.

q	pressing on → Fig.

21 -

Circlip

q	replace → Electronic Catalogue of Original Parts

q	Determine thickness → Fig.

22 -	Cylindrical-roller bearing

q	with circlip

q	removing → Fig.

q	pressing on → Fig.

q	Fitting position: the circlip in the bearing points towards the drive shaft

23 -	Clutch housing

24 -	Needle bearing

q	for 4th gear

q	installed on certain gearboxes

q	replace together with bushing Pos. 25 for 4th gear.

25 -

Bushing

q	for 4th gear needle bearing

q	replace together with needle bearing Pos. 24

q	installed on certain gearboxes

q	Pressing off bushing for needle bearing with sliding sleeve/synchronizer body for 3rd and 4th gear → Fig.

q	Pressing on bushing for needle bearing → Fig.

26 -

Spring

q	Fitting position → Fig.

27 -	Sliding sleeve 3rd and 4th gear

28 -	Synchronizer body for 3rd and 4th gear

29 -	Arresters for synchronizer body

q	(3 pieces)

30 -

Spring

q	Fitting position → Fig.

31 -	Arresters for synchronizer body

q	(3 pieces)

32 -	5th gear synchronizer body

33 -	5th gear sliding sleeve

34 -

Stop ring

q	prevents the arresters from wandering

q	removing → Fig.

q	installing → Fig.

Pull out the cylindrical-roller bearing from the clutch housing –  When removing compress circlip -arrow- of the cylindrical-roller bearing with pliers -C-. A -  Countersupport, e.g. -Kukko 22/1- B -  Interior extractor 30...37 mm, e.g. -Kukko 21/5-

Press the cylindrical-roller bearing into the clutch housing –  Support the clutch housing by positioning pipe section -MP3-450 (VW 415A)- (not visible in figure) directly under the bearing support. –  When inserting compress circlip -arrow- of the cylindrical-roller bearing with pliers -A-. –  Remove pliers before the cylindrical-roller bearing is in fitting position. The circlip must lock into the clutch housing slot.

Press out the bearing support for grooved ball bearing –  Slide the pressure plate -T10084A- sideways up to stop onto the drive shaft. –  Insert the pressure plate -T10081 - centering pins in the holes of the drive shaft and output shaft.   Note Always replace bearing support with grooved ball bearing → Electronic Catalogue of Original Parts.

Press off inner ring of the cylindrical-roller bearing with the 4th gear sliding gear –  First remove the circlip. –  Insert separating device -A- behind the running gearing (not the engaging gearing) of the 4th gear and press off. A -  Separating device 12...75 mm, e.g. -Kukko 17/1-

If present, press the circlip -1- out of the slot A -  Protective glove   WARNING Prevent uncontrolled ejection of the circlip.   Note t  The illustration shows the output shaft. The removal of the circlip is identical to the removal of the drive shaft. t  On certain gearboxes the circlips are not fitted above and below the 3rd and 4th gear synchronizer body.

Press off sliding sleeve and synchronizer body for the 3rd and 4th gear –  Press off together 3rd gear sliding gear, sliding sleeve/synchronizer body and bushing for needle bearing 4th gear, if present.   Note On certain gerboxes a bushing is fitted additionally to the needle bearing 4th gear.

Disassembling and assembling the sliding sleeve and 3rd and 4th 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 deeper recesses -arrow A- of the arresters in the synchronizer body and the recesses -arrow B- in 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 the arresters in the deeper recesses -arrows- and mount the springs with 120° offset.    The angled end of the springs must grip into the hollow arrester of the synchronizer body.

Fitting position of the sliding sleeve and 3rd and 4th gear synchronizer body The groove on the front side -arrow- points towards the 4th gear.

Check 3rd, 4th and 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-	1.1…1.7 mm	0.5 mm

Press on the synchronizer body with the 3rd and 4th gear sliding sleeve

If present, replace circlip   Note t  The illustration shows the output shaft. The installation of the circlip is identical for the drive shaft. t  On certain gearboxes the circlips are not fitted above and below the 3rd and 4th gear synchronizer body. –  Place 4th gear synchronizer ring in the sliding sleeve and synchronizer body.

If present, press on the bushing -A- for the 4th gear needle bearing –  Subsequently place 4th gear needle bearing with 4th gear sliding gear and thrust washer.

Press on the inner ring -A- for the cylindrical-roller bearing –  Insert determined circlip → Fig..

Determining the circlip –  Insert circlip -A- with a thickness of 2.0 mm in the slot of the drive shaft and push upwards -arrow-. –  Measure dimension between inner ring -B- and positioned circlip -A- using a feeler gauge -C-. –  Remove the circlip used to take the measurement. –  Determine the first circlip required according to the table.   Note Assign circlips via → Electronic Catalogue of Original Parts. Circlips available

Measured value (mm)	Circlip thickness (mm)	Axial play (mm)
0,05…0,10	2,0	0,05…0,15
0,15…0,20	2,1	0,05…0,15
0,25…0,30	2,2	0,05…0,15
0,35…0,40	2,3	0,05…0,15
0,45…0,50	2,4	0,05…0,10

Press on the bearing support for grooved ball bearing –  Before pressing on the bearing support heat it to approximately 100 °C.

Press on the bushing -A- for the 5th gear needle bearing

Removing the stop ring –  Unclip the hook -A- of the stop ring from the synchronizer body with a screwdriver.

Disassembling and assembling the sliding sleeve and 5th gear synchronizer body 1 -  Spring 2 -  Arresters for synchronizer body 3 -  Synchronizer body, fitting position: the groove on the front side -arrow A- and the wide collar -arrow B- point towards the 5th gear. 4 -  Sliding sleeve 5 -  Stop ring –  Slide the sliding sleeve over the synchronizer body.    The deeper recesses -arrow C- of the arresters in the synchronizer body and the recesses -arrow D- in the sliding sleeve must be positioned above one another.

Installing the stop ring –  Press the stop ring onto the flywheel type belt pulley fitting tool -MP9-400-. –  Insert the stop ring together with the flywheel type belt pulley fitting tool in the synchronizer body with 5th gear sliding sleeve (Observe fitting position → Fig.). The hooks -arrows 1- are locked in the recesses -arrows 2- for arresters of the synchronizer body. –  Push the stop ring down until the hooks click into position.