Skoda Workshop Service and Repair Manuals

Assembling the rear final drive

–  First press the plate housing out of the cover for Haldex coupling.

–  Insert head bevel gear with drive shaft. –  Position left cover with new O-ring. –  Moisten O-ring with gear oil. –  Tighten screws to tightening torque → Item.

–  Insert right cover with differential gear and new O-ring -A- (moisten with gear oil), screw in the screws uniformly crosswise. –  Tighten screws to tightening torque → Item. –  Press the ventilation into the rear axle housing.

Push out the old circlip from the flange shaft groove with the new circlip -A-. –  Drive in the flange shaft on the right and left with a plastic hammer. –  Fit on adjusting washer S3.

–  Insert new O-ring -A- into the round slot of the secondary shaft housing and moisten with gear oil. –  Position secondary shaft housing with shank bevel gear. Fitting position: The oil filter mount is located above the oil filler plug.

–  Cover all the nuts -arrows- with locking agent -D 197 300 A1- and tighten crosswise in stages to tightening torque → Item.

–  Insert the washer -1- for axial needle bearing with the shoulder pointing towards the axial needle bearing -2--arrow A- into the secondary shaft housing. –  Then fit on the axial needle bearing -2-. –  Subsequently insert the thrust washer -3- with the larger smooth surface -arrow B- pointing towards the hub -4-. –  Now push the hub -4- onto the shank bevel gear with the 3 holes -arrow C- pointing upward.

–  Afterwards, fit the first inner plate -2- into the secondary shaft housing -1-. –  After this, insert the first outer plate -3- and subsequently position the remaining 6 inner plates and 6 outer plates.

–  When installing the cam disc -A-, make sure that the cam path remains visible. Fitting position: The reverse teeth of the hub -arrows- must thereby grip into the interrupted spacing of the 3 teeth.

–  When inserting -arrows-, turn the plate housing -A- and while doing so guide the housing to the cam disc/plate package up to the stop. –  Place the 3 rollers -B- into the recesses of the plate housing. –  Then place the 6 castors -C- into the plate housing as well.   Note The rollers and castors can only be inserted in one position because of the shape inside the plate housing. –  Then install the ring -D-.

–  Position the thicker thrust washers -A- onto the castors and rollers in the plate housing. –  After this, fit on the axial needle bearings -B- and the thinner thrust washers -C- for axial needle bearing.   Note t  These individual axial needle bearing packages 1 through 3 are assigned to the diameters of the pistons for Haldex coupling. t  Make sure that the gap -arrow- between the axial needle bearing packages 2 and 3 is of equal size all around. –  Insert the disc spring -4- with the large Ø (concave side) pointing towards the ring ( → Anchor, fig. N39-1043).

–  Moisten O-rings -arrows A- and -arrow B- with high efficiency oil for Haldex coupling and insert them into the cover for Haldex coupling. –  Pull out the middle piston -arrow C- approx. 5 mm uniformly across the entire circumference.

–  Carefully position the cover for Haldex coupling -1- onto the secondary shaft housing -2-. –  Screw in the fixing screws -arrows- crosswise in stages, each time 1/2 turn. –  The gap -arrow A- must decrease uniformly.   Note The screws must not be tight when there is a gap. The axial needle bearing packages could have slipped towards the piston. Then remove the cover again and re-align the axial needle bearing. –  Tighten screws to tightening torque → Item.

–  Attach the cover -A- with new gasket to the secondary shaft housing -arrows-. Thus pay attention to the different versions of the covers, → Fig.

–  Install oil filter -4- and tighten to tightening torque → Item. –  Install pump for Haldex coupling -V181--3- and four-wheel drive control unit -J492--2-. Tighten screws -arrows A- and -arrows B- to tightening torque → Item. –  Mount plug -1- for pump for Haldex coupling. –  Before installing, lightly oil new gasket ring on the outside diameter and between the sealing lips with high efficiency oil -G 052 175 A1- for the Haldex coupling.

–  Drive in new gasket ring until flush. –  Install flange/propshaft.

–  Insert new nut with locking agent -D 000 600- and tighten to tightening torque → Item. A -  Screws M 10 x 20   Note When tightening the nut, counterhold the flange/propshaft via the stop plate -T30012/1A (3221/1A)- with the bolted counterholder -T30004 (3415)-. –  Remove rear final drive from assembly stand.

–  Install bracket -arrow- for electrical cable at rear final drive.