Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft up to gearbox manufacturing date 18 05 3 Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Thrust piece -MP3-411 (VW 454)- t  Pressure spindle -MP3-423 (VW 407)- t  Drive bushing -MP3-427 (40 - 21)- t  Pipe section -MP3-429 (2010)- t  Thrust piece -MP3-453 (VW431)- t  Thrust plate -MP3-467 (40-105)- t  Pipe section -MP3-4012 (VW 416 B)- t  Washer -MP6-415 (3260)- t  Retaining plate -T30027 (VW 801)- t  Knock-in bushing -T30034 (41 - 501)- t  Thrust piece -T30042 (2050)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/7- t  Interior extractor 46...58 mm, e.g. -Kukko 21/7- t  Separating device 22...115 mm, e.g. -Kukko 17/2- t  Extractor, e.g. -Kukko 18/1- t  Countersupport e.g. -Kukko 22/2-

t	When installing new pinions observe the technical data → Chapter.

t	If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be reset. Setting overview → Chapter.

t	Both tapered-roller bearings are replaced together.

1 -	Gearbox housing

2 -	Adjusting washer

q	Determine thickness → Chapter

3 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -

Circlip

q	determine once again when replacing the tapered-roller bearing Pos. 5 and the drive shaft Pos. 8 → Fig.

5 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

6 -	5th gear pinion

q	pressing off → Fig.

q	pressing on → Fig.

7 -	3rd/4th and 6th gear pinion

q	pressing off → Fig.

q	pressing on → Fig.

8 -	Drive shaft

q	adjust → Chapter

9 -	Inner ring/tapered-roller bearing

q	pressing off → Fig.

q	pressing on → Fig.

10 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	Fitting position → Fig.

q	installing → Fig.

11 -	Clutch housing

Remove outer ring/tapered-roller bearing from gearbox housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing –  First position adjusting washer under outer ring. –  Support the gearbox housing with a thrust piece -T30042 (2050)- directly below the bearing support.

Removing inner ring/tapered-roller bearing A -  Protective jaws/vice –  First remove the circlip. –  Before fitting the extractor position the thrust piece -MP3-453 (VW431)- and the thrust washer -MP3-467 (40-105)- on the drive shaft.

Pressing out 5th gear pinion A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing out 3rd/4th and 6th gear pinion

Pressing off inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing on 3rd/4th and 6th gear pinion –  Heat pinion to approx. 100 °C. –  Press on the gear pinion forcefully so that the heat is not transfered immediately onto the drive shaft.

Press on inner ring/tapered-roller bearing

Pressing on 5th gear pinion   Note The nut on the 5th gear pinion must point upwards to the press-on tool.

Press on inner ring/tapered-roller bearing –  Determine the circlip → Fig. and install.

Determining the circlip –  Determine the thickest circlip - that can be fitted - and insert. The following circlips are available:

Thickness (mm)
1,79	1,92
1,83	1,95
1,86	1,98
1,89

Part number → Electronic Catalogue of Original Parts.

Remove outer ring/tapered-roller bearing from clutch housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Fitting position of outer ring/tapered-roller bearing in clutch housing Recesses for the lock washer (⇒ figure S35-0168) at outer ring/tapered-roller bearing -arrow A- and clutch housing -arrow B- must be positioned above one another.

Pressing on outer ring/tapered-roller bearing –  After the pressing in procedure, check if the lock washer -A- can be inserted into the recess.   Note The lock washer -A- must only be installed and screwed down after inserting the drive shaft.