Skoda Workshop Service and Repair Manuals

Removing and installing the gearbox Special tools and workshop equipment required t  Gearbox mount -3282- t  Adjusting plate -T30007- t  Adapter -MP3-419/40 (VW771/40)- t  Gearbox attachment device -MP3-478 (3336)- t  Assembly device -MP5-402 (3301)- t  Supporting device -MP9-200 (10-222A)- t  Grease -G 000 100- t  -Loctite 648- Removing –  Remove engine cover. –  Close oil filler inlet. –  Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding. –  Disconnect earth strap of the battery.

–  Remove the intake hose -1- from the lock carrier. –  Disconnect air hose -2- from hot air collector/exhaust manifold. –  Remove the intake hose -3- from the inlet connection/throttle valve control unit -arrow-. –  Remove the complete air filter housing, to do so release bolts -4- and -5-. –  Remove the earth strap from the top engine/gearbox connecting screw.

–  Unscrew bracket -1- from the gearbox and lay aside together with the lines. –  Remove engine speed sender -G28--2-. –  Remove slave cylinder -4-, lay to one side and secure with wire. Do not open line system.   Note Do not depress the clutch pedal. –  Remove starter -3- → Rep. Gr.27.

–  Disconnect the plug -arrow 1- from the speedometer sender -G22-. –  Unscrew the speedometer sender -G22--arrow 2- from the guide bush. –  Disconnect plug -arrow 3- from reversing light switch -F4-.

–  Remove Bowden cable and console from the gearbox towards the top, while doing so unscrew screws -A-, -B- and -C-. –  Unscrew all nuts from the engine/gearbox studs accessible from the top. –  Remove front right wheel and raise vehicle. –  Remove noise insulation completely.

–  Release double clamp -A- and separate the exhaust system.

–  Unbolt the pendulum support -1--arrows-. –  Remove the drive shafts -2- from the flange shafts, turn steering to full left lock and tie up left drive shaft as far as possible, do not damage the surface protection. –  Unscrew engine/gearbox connecting screws -3-.

–  Unscrew screw -A- from the gearbox console. –  Engage 4th gear -arrow-. –  Unscrew screw -B- so far until the shift finger -C- can be removed from the gearshift shaft.

–  Detach the support angle from the steering gear, to do so screw out the screws -1-. –  Tie up cable support with console. –  Unscrew bracket for PAS line from the gearbox.

–  Mark installation position of bolts -1- for right steering joint, otherwise the steering geometry must be checked. –  Release screws -1-. –  Unscrew the coupling rod -2- from the right track control arm -arrow-. –  Slightly press engine/gearbox forward. –  Now lay the right drive shaft towards the front and tie up on the assembly carrier.

–  Install supporting device -MP9-200 (10-222A)-. –  Take up the weight of the engine/gearbox unit at the spindles.

–  Unscrew the fixing screws -arrows- from the gearbox mount -A-.

–  Lower the engine/gearbox assembly at the two spindles max. 80 mm -a-.   Note Observe PAS line when displacing the engine/gearbox unit. Complete gearbox jack with gearbox mount -3282-, adjusting plate -T30007- for 002 gearbox and support elements as follows: –  Position adjusting plate -T30007- onto gearbox jack with gearbox mount -3282-.   Note Adjusting plate fits in one position only. –  Align arms of the gearbox mount with the holes in the adjusting plate. –  Screw in the mounting elements as shown on the adjusting plate.

–  Position gearbox jack below vehicle, arrow symbol on adjusting plate points in the direction of travel/vehicle. –  Align the adjusting plate parallel to the gearbox.

–  Screw the adapter -MP3-419/40 (VW771/40)-, as shown in the illustration, into the threaded bore of the clutch housing. –  Secure the gearbox on the gearbox support -3282- using screw -A-. –  Unscrew nut of rear engine/gearbox stud. –  Unscrew screw for front engine/gearbox fixation. –  Press gearbox off the engine and swivel towards the assembly carrier. –  Lower gearbox carefully, while doing so always correct the position via the spindles of the gearbox jack.   Note Observe PAS line when lowering the gearbox.

–  Screw down gearbox suspension device -MP3-478 (3336)- onto clutch housing with assembly device -MP5-402 (3301)-.

–  Adjust supporting arm at slide with locking pin. Number of visible holes = 8 -arrow- –  Raise gearbox with workshop crane and gearbox suspension device -MP3-478 (3336)-. –  Place down gearbox, e.g. in a transport container. Install –  Before installing, unscrew plug for gearbox oil inspection and pour in gear oil. Capacity and specification → Chapter. The installation of the gearbox occurs in reverse order. Observe the stress-free assembly bracket in the vehicle → Rep. Gr.10. –  After installing, check gear oil level → Chapter.   Note t  Clean splines of drive shaft and apply a thin film of grease -G 000 100-. t  When replacing the gearbox → Electronic Catalogue of Original Parts ensure the intermediate plate between the engine and gearbox is correctly installed. t  Check whether the dowel sleeves for centering the gearbox are present in the cylinder block; insert if necessary. t  Install starter and cables → Rep. Gr.27. t  Setting the shift mechanism → Chapter. Perform the following work after connecting the battery: t  on vehicles with radio encoding, carry out the coding t  re-set clock t  initialise power windows on vehicles fitted with power windows → Octavia Tightening torques

Gearbox to engine

Pos.	Nut/screw	Pieces	Nm
1	Nut M10	2	45
2	Nut M10	2	45
3 → Note	Screw M10	1	45
4	Screw M10	2	45

1)  Screw with threaded pin M8. -A- dowel sleeves

Bowden cable and console to top of gearbox

Screw -A- for console and guide bush (speedometer) to gearbox		20 Nm
Screw -B- and -C-		20 Nm

Console to bottom of gearbox

Screw -A-		20 Nm
Screw -B- for attaching the gearbox shift lever -C- to the gearshift shaft → Note		20 Nm

2)  Apply locking agent -Loctite 648- before installing.

Components		Tightening torque
Support angle - steering gear M8		25 Nm
Cover for gearbox housing - gearbox mount M12 → Note		80 Nm
Pendulum support - gearbox M10 → Note		40 Nm + 90°
Pendulum support - assembly carrier M8 → Note		20 Nm + 90°
Drive shaft - flange shaft (tighten crosswise in 2 stages) M8 → Note → Rep. Gr.40
Steering joint - track control arm M8 → Note		20 Nm + 90°
Coupling rod - track control arm		45 Nm
Starter - gearbox M8		25 Nm
Wheel bolts - wheel hub		120 Nm
Nut for attaching double clamp of exhaust system		40 Nm

3)  Always replace screws → Electronic Catalogue of Original Parts.