Skoda Workshop Service and Repair Manuals

Assembling gearbox

–  Insert differential gear -1-. –  Insert output shaft 5th/6th gear and reverse gear -2- together with reverse gear shift fork, 5th/6th gear shift rod -3- and reverse shaft -4-.

–  Take the output shaft gears 1 through 4 -3- with the gear shift rods -5- in the right hand, as shown in the figure. –  Slightly lift the differential gear with the left hand. –  At the same time a 2nd mechanic lifts the output shaft 5th/6th gear and reverse gear -2- together with the reverse shaft -4-. –  Insert the output shaft gears 1 through 4 in -the direction of the arrow-. The serrations of the output shafts and the final drive/differential gear must be in mesh. –  Now place the shafts together with a 2nd mechanic in their bearing assembly.

–  Position the drive shaft in the clutch housing and swivel -direction of arrow-.

–  Insert the lock washer -A- in the recess of the outer ring/tapered-roller bearing for drive shaft. –  Tighten new screw -arrow 2- to 12 Nm. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the clutch housing. –  Fit gearbox housing.

Install the gearshift shaft as follows: –  Put the shift rods into Neutral. –  Insert the gearshift shaft -1-. –  Align the gearshift shaft in such a way that the shift fingers are inserted into the shift rods. –  To do so align the bottom bearing -arrow- of the gearshift shaft through the hole for the cap. –  Screw the cap -A- with a screw -2- M8 x 60 mm to the bottom bearing for gearshift shaft -1-.

–  Insert cap -A- manually by alternatively tightening (1/2 turn) the screws -arrows-. –  Unscrew the screw -2- and for this operation screw in the original screw by hand. –  Fit gearshift shaft cover -B- and tighten the screws -4- to 20 Nm. –  Now tighten the screws for the cap to 20 Nm. –  Insert locking screw -3- for the sliding-block of the gearshift shaft with locking agent -D 000 600 A2 - and tighten to 15 Nm. –  Tighten reversing light switch -F4- to 20 Nm. Front-wheel-drive –  Install both flange shafts with pressure springs, stop discs and conical rings. Four-wheel drive –  Mount the left flange shaft. Continued for all vehicles –  If present, install the speedometer sender.

–  Drive in the gasket ring for the drive shaft. –  Install slave cylinder with release bearing and bleeder → Chapter. –  Shift through all gears consecutively. Four-wheel drive Install the angle gearbox as follows:

–  Always replace the O-ring for sealing the angle gearbox/manual gearbox -arrow A- and the O-rings for sealing the bushings for oil supply -arrow B- and -arrow C- and lightly oil. –  On the manual gearbox, grease the rigid serration at the differential gear with grease for plug serration of clutch disc -G 000 100-. –  Push angle gearbox fully onto the manual gearbox, while doing so centrically guide the serration of the drive shaft/angle gearbox together with the coupling sleeve/differential gear. –  Bring the serration of the right flange shaft and differential bevel gear also into alignment, if necessary turn at the flange shaft. –  If tooth positioning and centrical guidance are correct, the angle gearbox slips up to the stop against the manual gearbox. –  Do not pull angle gearbox with the fixing screws against the manual gearbox, otherwise the angle gearbox can tilt and the fixing eyes can break off.

–  Tighten the four connecting screws (only three are shown in the figure) of the angle gearbox on the manual gearbox to 40 Nm and torque a further 45 ° -arrows-. –  Tighten conical screw for right flange shaft with 6 mm socket insert, at least 190 mm long, to 25 Nm. While doing so, screw 2 screws into the flange and counterhold the flange shaft for example with a drift.   Note The conical screw for the right flange shaft can also be installed with the socket insert -V.A.G 1669-.