Skoda Workshop Service and Repair Manuals

Disassembling gearbox –  Place catch pan underneath.

–  Drain gear oil, to this end unscrew oil drain plug -arrow-.

–  Clamp the gearbox into the assembly stand. Pay attention to note.   Note Before fastening the gearbox for the first time, the gearbox holder must be reworked in accordance with the dimensions stated below.

–  Attach additional holes to gearbox holder.

-A-	= 118.5 mm
-B-	= 23.5 mm
Ø -C-	= 11.0 mm
-D-	= 40 mm
-E-	= 55 mm
-F-	= M10

Note

The gearbox can also be attached to the gearbox mount -T30109 (VW 353)- in combination with the retaining plate -T30108-.

–  Pull clutch push rod out of the drive shaft.

–  Mount supporting bridge -MP3-425 (30-211 A)- for drive shaft. A -  Counternut M12 –  Lift the pressing tool -T30087/2 (3367/2)- over the screw onto the drive shaft up to the stop and lock with nut -A-.

–  Remove the screw cap -arrow 1- from the gearbox housing cover. –  Unscrew the cover -arrow 2- for the gearbox housing (6 screws).   Note One of the 6 screws is located inside the cover.

–  Remove drive -B- for speedometer. Up to gearbox manufacturing date 02 08 8 –  Remove locking screw for gearshift shaft -A- with reversing light switch -F4--arrow-.

As of gearbox manufacturing date 03 08 8 –  Remove locking screw for gearshift shaft -2-. –  Remove switch for reversing lights -F4--1-. Continued for all gearboxes

–  Unscrew cover for the gearshift shaft e.g. with a spark plug wrench -A- or with 27 mm wrench socket and take out with pressure spring. –  Put the gearshift shaft in neutral position and pull out of the gearbox housing.

–  Unscrew torx screw to secure the reverse shaft support -arrow-.

–  Remove the left flange shaft. –  Remove the flange shaft with pressure spring, stop disc and conical ring.

–  Engage 5th gear -arrow 1-. –  Engage reverse gear -arrow 2- (front shift fork to the bottom).

–  Unscrew screw for synchronizer body -arrow- using a 12 mm polygon head wrench.

–  Release lock washer for shift tube.

–  Screw out the shift tube - towards the left - from the shift fork.   Note Do not pull the shift rod out of the shift tube.

–  Remove synchronizer body completely with sliding gear and shift fork for 5th gear or slightly release with two tyre levers, thus do not damage the housing of the sealing surface. –  Observe thrust washer for 5th gear sliding gear below the synchronizer body.

–  Remove circlip and thrust washer -A- for 5th gear pinion.

–  Remove 5th gear pinion. -A-Two-arm extractor, e.g. -Kukko 20/10- with hook -Matra V/170-.

–  Uncrew tensioning plate (bracket for ball bearing/drive shaft) -arrows-. –  Remove the fixing screws for the gearbox housing on the clutch housing.

–  Attach assembly device -MP3-422 (VW 391)- with screw (M8) -arrow- to gearbox housing. First remove dowel sleeve if necessary. –  Secure the extractor -MP3-432 (3042)- as illustrated. l  Insert the spindle of the extractor precisely into the hole of the drive shaft. –  Detach gearbox housing.

–  Pull shift rod -A- out of the hole in the clutch housing and swivel out the gearshift forks -B-. –  Remove circlip for 4th gear pinion/output shaft.

–  Remove 4th gear pinion. -A-Two-arm extractor, e.g. -Kukko 20/10- with hook -Matra V/170-.

–  Remove drive shaft -A- completely.   Note The reverse gear -B- must not be engaged.

–  Remove circlip -B- for 3rd gear pinion.

–  Detach 3rd gear pinion with 2nd gear sliding gear. -A-Two-arm extractor, e.g. -Kukko 20/10- with hook 250 mm clamping depth. –  Remove synchronizer ring and needle bearing. –  Drive out reverse shaft support via screwed in bolt -arrow- using a plastic hammer. –  Remove reverse gear from reverse lever.

–  Remove synchronizer body/sliding sleeve and 1st gear sliding gear together with 2nd gear inner ring/needle bearing. -A-Two-arm extractor, e.g. -Kukko 20/10- with hook 250 mm clamping depth.

–  Unscrew bearing support -arrows- and remove output shaft. Observe thrust washer -1-. –  Remove right flange shaft and take out differential gear.   Note t  Removing is identical to the left flange shaft → Anchor. t  Check the correct position of the rivets for the differential gear. In the event that the riveted joints are loose, the fastening set (screwed connection of pinion for final drive to differential gear housing) must be installed → Chapter.