Skoda Workshop Service and Repair Manuals

Disassembling and assembling output shaft 5th/6th gear and reverse gear

t	If the output shaft or tapered-roller bearing is replaced, it is necessary to adjust the output shaft → Chapter.

t	Replace both tapered-roller bearings together.

1 -	Clutch housing

2 -

Washer

q	always 0.65 mm thick

3 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

5 -	Output shaft

q	5./6. and reverse gear

q	adjust → Chapter

6 -	Reverse gear synchronizer body

q	remove → Fig.

q	Fitting position → Fig.

q	pressing on → Fig.

7 -

Circlip

8 -	Reverse gear sliding sleeve

q	with synchronizer ring

9 -	Needle bearing

q	for reverse gear sliding gear

10 -	Reverse gear sliding gear

11 -

Bushing

q	pressing off with reverse gear sliding gear → Fig.

q	Fitting position: broad collar of bushing points to the reverse gear sliding gear

q	pressing on → Fig.

12 -

Circlip

13 -	Needle bearing

q	for 6th gear

14 -	6th gear sliding gear

15 -	6th gear synchronizer ring

q	check for wear → Fig.

16 -	Sliding sleeve with 5th and 6th gear synchronizer body

q	after removing the circlip -Pos. 17- press off with the 6th gear sliding gear → Fig.

q	disassembling → Fig.

q	Assembling sliding sleeve/synchronizer body → Fig. and → Fig.

q	pressing on → Fig.

17 -

Circlip

18 -	Needle bearing

q	for 5th gear

19 -	5th gear synchronizer ring

q	check for wear → Fig.

20 -	5th gear sliding gear

21 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

22 -

Circlip

q	determine → Fig. when replacing the tapered-roller bearing -Pos. 21- and the output shaft -Pos. 5-

23 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

24 -	Adjusting washer

q	Determine thickness → Chapter

25 -	Gearbox housing

26 -

Spring

q	Fitting position → Fig.

27 -	Sliding sleeve

28 -	Synchronizer body

29 -	Arresters (3 pieces)

q	Fitting position → Fig.

Remove outer ring/tapered-roller bearing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-   Note After pulling out the washer check for damage, if necessary replace.

Press outer ring/tapered-roller bearing into the clutch housing –  Position washer under outside ring. –  Support the clutch housing with a pressure plate -T30091- directly below the bearing support.

Removing inner ring/tapered-roller bearing –  First remove the circlip. –  Before fitting the extractor position thrust piece -MP3-453- and pressure plate -MP3-467- on output shaft.

Pressing off 5th and 6th gear synchronizer body/sliding with sliding gear for 6th gear –  First remove the circlip.

Pressing off bushing -A- with reverse gear sliding gear –  First remove the circlip.

Pressing off reverse gear synchronizer body –  First remove the circlip. A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Removing inner ring/tapered-roller bearing –  Before fitting the extractor, position pressure plate -MP3-410- on the output shaft.

Fitting position of reverse gear synchronizer body The stop -arrow A- for the reverse gear sliding sleeve points towards the output shaft serration -arrow B-.

Pressing on reverse gear synchronizer body –  Install circlip.

Pressing on bushing -A- Fitting position: Broad collar points towards the reverse gear sliding gear. –  Install circlip.

Check 5th and 6th gear synchronizer ring for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.

Clearance -a-	Fitting dimension	Wear limit
5th and 6th gear	1.0 … 1.7 mm	0.5 mm

Disassembling and assembling the sliding sleeve and 5th and 6th gear synchronizer body 1 -  Spring 2 -  Arresters 3 -  Sliding sleeve 4 -  Synchronizer body –  Slide the sliding sleeve over the synchronizer body. The recesses for the arresters on the synchronizer body and the sliding sleeve must be positioned above one another.

Assembly of the sliding sleeve/5th and 6th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and mount springs with 120° offset. The angled end of the spring must grip into the hollow arrester.

Press on the sliding sleeve and 5th and 6th gear synchronizer body –  Install circlip.

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)	Part number
1,79	02M 311 187 G
1,83	02M 311 187 F
1,86	02M 311 187 E
1,89	02M 311 187 D
1,92	02M 311 187 C
1,95	02M 311 187 B
1,98	02M 311 187 A

Press on inner ring/tapered-roller bearing

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 –  Support the gearbox housing with a pressure plate -T30042- directly below the bearing support.