skoda Workshop Repair Guides

Skoda Workshop Service and Repair Manuals

Repairing the clutch housing > < Repairing the gearbox housing for gearbox up to gearbox manufacturing date 06.03
Repairing the gearbox housing for gearbox as of gearbox manufacturing date 07.03
Repairing the gearbox housing for gearbox as of gearbox manufacturing date 07.03
Special tools and workshop equipment required
t  Drive bushing -MP3-402 (VW 244B)-
t  Multi-purpose tool -MP3-419 (VW 771)-
t  Pressure plate -MP3-420 (3124)-
t  Thrust piece -MP3-423 (VW 407)-
t  Guide piece -MP3-454 (VW 439)-
t  Gearbox mount -MP3-501-
t  Pipe section -MP3-4012 (VW 416B)-
t  Assembly stand -MP9-101-
t  Drift -T10168-
t  Drift -T10169-
t  Pressure plate -T10203-
t  Retaining plate -T30027 (VW 801)-
t  Guide bolt -T30074 (10-15)-
t  Spindle -T30100 (3290)-
t  Torque wrench
t  Interior extractor 14.5...18.5 mm e.g. - Kukko 21/2-
t  Interior extractor 23.5...30 mm e.g. - Kukko 21/4-
t  Countersupport e.g. -Kukko 22/2 -
   
1 - Gearbox housing
q   if replaced: Setting the output shafts and differential gear → Chapter
q   as of gearbox manufacturing date 08 01 6 the threaded bores for the oil filler plug and oil drain plug are modified from M24 x 1.5 to M22 x 1.5
q   modified as of gearbox manufacturing date 10 04 6 in the area of the support for the grooved ball bearing/drive shaft → Chapter
q   assign components via → Electronic Catalogue of Original Parts
2 - Cap
q   removing → Fig.
q   inserting → Fig.
3 - Oil drain plug
q   pay attention to different version → Fig.
q   Splined nut, 45 Nm
q   Allan screw, 30 Nm
4 - Gasket ring
q   always replace → Electronic Catalogue of Original Parts
q   no longer applicable for oil filler plug or oil drain plug with thread M22 x 1.5 mm
5 - Oil filler plug
q   pay attention to different version → Fig.
q   Splined nut, 45 Nm
q   Allan screw, 30 Nm
6 - Locking angle
q   for setting the gearshift mechanism → Chapter
q   can be replaced without disassembling gearbox
q   removing → Fig.
q   Fitting position → Fig.
q   inserting → Fig.
7 - Bushing
q   for selector rods
q   removing → Fig.
q   inserting → Fig.
8 - Serrated sleeve
q   press out with gearbox disassembled → Fig.
q   drive out without disassembling gearbox → Fig.
q   inserting → Fig.
9 - Needle bushing
q   for reverse shaft
q   replace after each disassembly → electronic catalogue of original parts
q   removing → Fig.
q   installing → Fig.
10 - Outer ring/tapered-roller bearing
q   for output shaft 5th/6th and reverse gear
q   removing and installing → Chapter
q   if replaced: Setting output shaft 5th/6th and reverse gear → Chapter
11 - Adjusting washer
q   for output shaft 5th/6th and reverse gear
q   Setting overview → Chapter
12 - Outer ring/tapered-roller bearing
q   for output shaft gears 1 through 4
q   removing and installing → Chapter
q   if replaced: Setting output shaft gears 1 through 4 → Chapter
13 - Adjusting washer
q   for output shaft gears 1 through 4
q   Setting overview → Chapter
14 - Outer ring/tapered-roller bearing
q   for differential
q   removing and installing → Chapter
q   if replaced: Adjusting the differential gear → Chapter
15 - Adjusting washer
q   for differential
q   Setting overview → Chapter
16 - Bushing
q   for gearshift shaft
q   removing → Fig.
q   inserting → Fig.
17 - Plug
q   drive out with drift
q   inserting → Fig.
18 - Gasket ring
q   for left flange shaft
q   replace → Chapter

   
Different versions of oil filler plug and oil drain plug.
I - Oil filler plug and oil drain plug with internal serration
II - Oil filler plug and oil drain plug with Allan key
  Note
The oil filler plugs or oil drain plugs with thread M22 x 1.5 are installed on gearboxes as of gearbox manufacturing date 08 01 6. The gasket ring is no longer applicable for these screws. Assign components via → Electronic Catalogue of Original Parts.
  N34-10041
Removing cap -A-
–  Push the rubber through the middle of the cap using a screwdriver -B- and lever out the cap -direction of arrow-.
  S34-0709
Drive in cap up to the stop
  S34-0710
Removing locking angle for gearshift shaft
–  Remove angle in the released position.
–  Insert a screwdriver -A- in the hole of the locking angle -B-.
–  Lever out inner part of locking angle in -the direction of the arrow-.
  S34-0711
Fitting position of locking angle
–  The marking on the locking angle -arrow- must point to the connection of the slave cylinder -1-.
The dimension -a- must be approx. 45°.
  S34-0712
Drive in locking angle -arrow- for gearshift shaft up to the stop of the tool
  Note
Locking angle must be released during drive-in procedure.
  S34-0713
Remove bushing for gear shift rod
A - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
B - Countersupport, e.g. -Kukko 22/2-
  S34-0714
Drive in the bushing for the shift rod up to the stop of the tool
  S34-0715
Press serrated sleeve -A- out of gearbox housing
–  Position the gearbox housing on the pressure plates -MP3-406 - and -MP3-407- in such a way that the dowel sleeves in the gearbox housing are not damaged.
  S34-0835
Drive out serrated sleeve without disassembling gearbox with guide bolts -T30074-
–  First remove locking screw and gearshift shaft.
–  Turn the gearbox in such a way that the serrated sleeve does not fall into the gearbox.
  S34-0836
Drive in serrated sleeve up to the stop of the tool
Only drive in serrated sleeve with the drift -T10169-, with the gearbox housing mounted on the clutch housing.
  S34-0847
Pull needle bushing for reverse shaft out of the gearbox housing
A - Interior extractor 23.5...30 mm, e.g. -Kukko 21/4-
B - Countersupport, e.g. -Kukko 22/2-
  Note
The needle bushing is damaged when removed and must be replaced.
  S34-0718
Pressing in needle bushing -A- in the gearbox housing
–  During press-in procedure, position the thrust washer -B- of the reverse shaft onto the needle bushing -A-.
–  Support the gearbox housing with a pipe section -MP3-4012 - directly below the bearing support.
  S34-0719
Remove bushing for gearshift shaft
–  Hold spindle of assembly device -T30100- and turn nut -B-.
A - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
  S34-0838
Drive in the bushing -A- for the gearshift shaft up to the stop of the tool.
  S34-0721
Driving in plug
–  Drive in plug -1- with the mandrel -T30083- to the dimension -a- = approx. 3 mm below the upper edge of the housing.
  S34-0722

Repairing the clutch housing > < Repairing the gearbox housing for gearbox up to gearbox manufacturing date 06.03