Skoda Workshop Service and Repair Manuals

Disassembling and assembling clutch “D/G” with free wheel Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP5-402/4 (3301/4)- from assembly device -MP5-402 (3301)- t  Prestressed tool -T10285- t  Assembly clamp -T10289- t  Plate -T10292- t  Plate -T10293- t  Digital depth gauge, e.g. -VAS 6087-

Dismantling l  The clutch “D” points upwards. –  Remove circlip -1- and take the plate package -2- out of the cylinder “D/G”.

–  Turn cylinder “D/G”. l  The clutch “G” points upwards (disc spring of clutch “G” is visible). –  Remove circlip -1- and take the plate package -2- out of the cylinder “D/G”.

–  Position cylinder “D/G” onto the pressure plate -MP5-402/4 (3301/4)- below the workshop press. While doing so, the clutch “G” must point upwards. –  Press down the disc spring with assembly clamp -T10289 - below the workshop press. –  Remove circlip -1-, the thrust washer and the disc spring. –  Release the workshop press.

Note Carefully remove cylinder “D/G” from the workshop press, while doing so secure the free wheel against falling down.   WARNING Wear safety glasses. –  Carefully press piston “G” with compressed air out of the cylinder “D/G”.

–  Press the free wheel inner race -2- out of the cylinder “D/G”-pos. 1--arrow-, if necessary release by applying slight blows with a plastic hammer. –  Remove cylinder “D/G” from free wheel.

–  Turn cylinder “D/G” l  The cylinder “D” points upwards.   WARNING Wear safety glasses. –  Carefully press piston “D” with compressed air out of the cylinder “D/G”.

–  Disassembling free wheel: 6 -  Disc spring 5 -  Retaining washer 4 -  Free wheel with free wheel cage 3 -  Rectangular rings 2 -  Sealing rings 1 -  Free wheel inner race

Assembling together   Caution Before assembling, check the components of the free wheel, the clutch “D” and the clutch “G” for wear and damage → Chapter. –  Replace O-rings -2- and -4- for piston “D”-pos. 3- → Electronic Catalogue of Original Parts. –  Press piston “D”-pos. 3- up to the stop into the cylinder “D/G”-pos. 1-.

–  Insert corrugated spring -2- into the cylinder “D/G”-pos. 1-. –  Alternatively insert the outer plates -3- and the lining plates -4-. –  Insert the thick outer plate -5-   Note Make sure that the round edges of the thick outer plate point to the lining plate -4- and not to the circlip -6-. This improves the contact surface for the circlip. –  Insert circlip -6-.

Set air play of clutch “D” –  Place clutch “D/G” onto the prestressed tool -T10285-. l  The clutch “D” points upwards. –  Place the plate -T10293- onto the outer plate of the clutch “D”. l  The plate -T10293- should not touch the circlip. –  Insert pressure box -T10285/1- with its centering pin into the hole of the plate -T10293-. –  Align clutch “D/G” on the plate of the prestressed tool. l  The pressure box must be positioned centrically below the pressure plate of the spindle. –  Turn the spindle of the prestressed tool to the bottom. l  The markings at inspection hole of the pressure box must be flush -arrow-. –  Place digital depth gauge -VAS 6087- at upper edge of cylinder “D/G” , as shown in the fig. –  Align the measuring tongue of the digital depth gauge on the outer plate and note down. –  Mark the support point at cylinder “D/G”. –  Repeat the measurement at 2 other points of the outer plate each offset by 120° and mark the support points. –  Take the average value from the 3 measurements under load. –  Release the spindle and remove the plate -T10293-

–  Grip with both hands in the clutch “D” and pull the plate package up to the stop to the top. –  In case of pulled-up plate package, measure at one of the marked points the distance between the top edge of the cylinder “D/G” and the outer plate (second mechanic required). –  Repeat the measurement at the two other marked points. –  Make an average value from the 3 measurements for pulled-up plate package. –  Determine the air play according to the following calculation methods:

	Average value of measurements under load (value 1 + value 2 + value 3) : 3
–	Measurements for pulled-up plate package (value 1 + value 2 + value 3) : 3
=	Air play

–  Deduct the average value of measurements for pulled up plate package from average value of measurements under load.

Air play of clutch “D”

Gearbox code letters	Specification
EYF, EZY, FAD, FNL	2.29 … 2.59 mm
FEV	1.92 … 2.22 mm

If the specified value is not reached: –  Determine new circlip -1- according to the following table.   Note In the figure, do not pay attention to -pos. 2-. l  Air play too low: Insert thinner circlip. l  Air play too high: Insert thicker circlip.

Available circlips - thickness in mm
2.2	3.0	3.8
2.4	3.2	4.0
2.6	3.4	4.2
2,8	3,6

–  Check once again the air play after inserting the circlip.

–  Once the correct circlip is determined, remove the circlip -1- and take the plate package -2- out of the cylinder “D/G”.

–  Replace the O-rings -2- and the rectangular rings -3- on the free wheel inner race -1- → Electronic Catalogue of Original Parts. 4 -  Free wheel with free wheel cage 5 -  Retaining washer 6 -  Disc spring –  Before inserting the O-rings and the rectangular rings, thinly coat with vaseline. Only use vaseline, other types of lubricant will cause the gearbox hydraulic control system to malfunction. –  Make sure that the rectangular rings are fully seated into the slots of the free wheel inner race.

–  Insert the free wheel inner race -2- into the free wheel with free wheel cage -1--in direction of arrow A-. –  To do so turn the free wheel inner race -2- from the reverse side (below the area of the serration) -arrow B-, in -direction of arrow C- when inserting.

–  Put cylinder “D/G”-pos. 1- onto 2 squared timbers of approx. 40 mm. l  The cylinder “D” points upwards. –  Insert the disc spring -2- and the retaining washer -3- into cylinder “D/G”. l  The pegs on the retaining washer point to the cylinder “D/G” and must be inserted into the recesses of the cylinder “D/G” –  Take hold of the free wheel -4- in such a way that the free wheel inner race can no longer slip out. –  Then insert the free wheel inner race, to do so press the serration of the free wheel inner race into the serration of the cylinder “D/G”.   Note t  If the free wheel with free wheel cage slips to the bottom when inserting the free wheel inner race, it is positioned again onto the free wheel inner race. t  After insertion, the free wheel with free wheel cage must only have a low axial play.

–  Carefully turn the cylinder “D/G”-1-, to do so secure the free wheel inner race against slipping out. l  The cylinder “G” points upwards. –  Position cylinder “D/G” onto the pressure plate -MP5-402/4 (3301/4)-. –  Replace O-rings -2- and -4- for piston “G”-pos. 3- → Electronic Catalogue of Original Parts. –  Press piston “G”-pos. 3- up to the stop into the cylinder “D/G”. –  Fit on the disc spring -5- and the pressure spring -6-. 7 -  Circlip

–  Position the cylinder “D/G” with the pressure plate -MP5-402/4 (3301/4)- below the workshop press. –  Press down the disc spring with assembly clamp -T10289 - below the workshop press. –  Push the thrust washer -pos. 6- ⇒ previous fig. “A37-10345” fully downwards. l  The teeth of the thrust washer must grip into the serration of the free wheel inner race. –  Insert the circlip -1-. –  Make sure that the circlip is tightly fitted into the slot of the free wheel inner race, if necessary press circlip with a screwdriver into the slot. –  Release the workshop press. –  Press down once again the disc spring to check if the free wheel is correctly inserted. l  The thrust washer -pos. 6- ⇒ previous fig. “A37-10345” must move. l  The free wheel with free wheel cage must turn in clockwise direction.

–  Insert the corrugated spring -2- into the cylinder “D/G”-pos. 1-. l  The cylinder “G” points upwards. –  Alternatively insert the outer plates -3- and the lining plates -4-. –  Insert the thick outer plate -5-   Note Make sure that the round edges of the thick outer plate point to the lining plate -4- and not to the circlip -6-. This improves the contact surface for the circlip. –  Insert circlip -6-.

Set air play of clutch “G” –  Place clutch “D/G” onto the prestressed tool -T10285-. l  The clutch “G” points upwards. –  Place the plate -T10292- onto the outer plate of the clutch “G”. l  The plate -T10292- should not touch the circlip. –  Insert pressure box -T10285/1- with its centering pin into the hole of the plate -T10292-. –  Align clutch “D/G” on the plate of the prestressed tool. l  The pressure box must be positioned centrically below the pressure plate of the spindle. –  Turn the spindle of the prestressed tool to the bottom. l  The markings at inspection hole of the pressure box must be flush -arrow-. –  Place digital depth gauge -VAS 6087- at upper edge of cylinder “D/G” , as shown in the fig. –  Align the measuring tongue of the digital depth gauge on the outer plate and note down. –  Mark the support point at cylinder “D/G”. –  Repeat the measurement at 2 other points of the outer plate each offset by 120° and mark the support points. –  Take the average value from the 3 measurements under load. –  Release the spindle and remove the plate -T10292-

–  Grip with both hands in the clutch “G” and pull the plate package up to the stop to the top. –  In case of pulled-up plate package, measure at one of the marked points the distance between the top edge of the cylinder “D/G” and the outer plate (second mechanic required). –  Repeat the measurement at the two other marked points. –  Make an average value from the 3 measurements for pulled-up plate package. –  Determine the air play according to the following calculation methods:

	Average value of measurements under load (value 1 + value 2 + value 3) : 3
–	Measurements for pulled-up plate package (value 1 + value 2 + value 3) : 3
=	Air play

–  Deduct the average value of measurements for pulled up plate package from average value of measurements under load.

Air play of clutch “G”

Gearbox code letters	Specification
EYF, EZY, FNL	1,79 … 2,08 mm
FAD, FEV	1.33 … 1.62 mm

If the specified value is not reached: –  Determine new circlip -1- according to the following table.   Note In the figure, do not pay attention to -pos. 2-. l  Air play too low: Insert thinner circlip. l  Air play too high: Insert thicker circlip.

Available circlips - thickness in mm
1.8	2.4	3.0
2.0	2.6	3.2
2.2	2.8	3.4

–  Turn clutch “D/G”. l  The clutch “D” points upwards. –  Mount plates for clutch “D” with the newly determined circlip as follows:

–  Insert corrugated spring -2- into the cylinder “D/G”-pos. 1-. –  Alternatively insert the outer plates -3- and the lining plates -4-. –  Insert the thick outer plate -5-   Note Make sure that the round edges of the thick outer plate point to the lining plate -4- and not to the circlip -6-. This improves the contact surface for the circlip. –  Insert circlip -6-.