Skoda Workshop Service and Repair Manuals

Disassembling gearbox –  Position a catch pan under the gearbox. –  Drain out gear oil.

–  Attach gearbox to gearbox mount -MP3-501- with screws -arrows A- and nuts -arrows B- → Anchor. –  Turn gearbox in the assembly support to horizontal position.

–  Release screw -1- and remove the leaf spring -2-. –  Remove the clutch release lever -3- with the release bearing -4-.   Note The -arrows B- point to the nuts for atatching the gearbox to the gearbox mount -MP3-501-.

–  Screw out screws -arrows- and remove the securing plate -1-. –  Pull a thin insulating hose or shrink hose onto the gearing of the drive shaft. –  Detach guide bushing -2- from gearbox housing. –  Remove the intermediate piece -3- from the gearbox housing.

–  Pull out the O-ring -arrow- using a small screwdriver.

–  The circlip -arrow- in front of the grooved ball bearing of the drive shaft then has to be removed.   Note t  For disassembling the gearbox, the grooved ball bearing for the drive shaft must not be removed. t  A defective grooved ball bearing for input shaft can be replaced on removed gearbox (not disassembled) according to the work sequence → Chapter. –  Put the gearshift shaft into Neutral.

–  Pull out both locking bushings -A- for the gearshift shaft.   Note t  Mark the locking bushings -A- so that they cannot be mixed up with the locking bushings for the shift rods. t  The locking bushings were changed shortly after start of the series → Anchor. –  Release screws -arrows- and remove cover for gearshift shaft -B-.

–  Push gearshift shaft -A- as far as the stop into the gearbox and at the same time pull out the cylinder pin -B-. –  Pull out the gearshift shaft. l  The shift rods remain in the idle position. –  Afterwards turn the gearbox in the assembly stand with the gearbox cover upwards.

–  Release screws -arrows 1- (for fixing bearing carrier), screw -arrow 2- (for fixing reverse shaft) and connecting screws -A- of gearbox cover to gearbox housing. –  Remove the gearbox cover -B- from the gearbox housing.

–  Remove reverse gear -1- and reverse shaft. –  Remove solenoid -2- from gearbox housing.

–  Attach the stop plate -T30097/1 (T10108/1)- to the right flange shaft with 2 screws M10 x 35 -arrows-. While doing so, place one nut M12 -A- between flange shaft and stop plate.

–  Turn gearbox in the assembly support to horizontal position. –  Attach the stop plate - T30012/1A (3221/1A)- to the left flange shaft with 2 screws M10 x 35 -A-. While doing so, place one nut M12 and washer -B- between flange shaft and stop plate. l  No gears must be engaged. –  Slacken the nut of the secondary shaft (output shaft) with a toggle -E-. The assistance of a 2nd mechanic is required for slackening the nut via the pipe section -D-.   Note The slackening torque of the nut can be around 500 Nm. C -  46 mm socket wrench insert with drive 3/4 inch. –  Turn the gearbox in the assembly support vertically.

–  Remove the locking bushings -1- through -4- for the shift rods. 1 -  Locking bushing for reverse gear shift rod 2 -  Locking bushing for 1st/2nd gear shift rod 3 -  Locking bushing for 5th/6th gear shift rod 4 -  Locking bushing for 3rd/4th gear shift rod

Detach clutch body with grooved ball bearing from secondary shaft. A -  Two-arm extractor, e.g. -Kukko 20/10- –  For this step, position the extraction hooks-B- at the clutch body, where no engaging gearing is present -arrow-. –  Remove the synchronizer rings for reverse gear.

–  Remove sliding sleeve -1- with gearshift fork -2- and reverse gear sliding gear.

Pulling off 1st gear sliding gear with thrust washer -C- and inner ring/needle bearing -D- for reverse gear sliding gear. A -  Two-arm extractor, e.g. -Kukko 20/10- B -  Extraction hook 250 mm –  Remove the needle bearing and the synchronizer rings for 1st gear.

Pulling off 2nd gear sliding gear -D- together with inner ring/needle bearing -E- for 1st gear sliding gear and gearshift fork -C- for 1st/2nd gear. A -  Two-arm extractor, e.g. -Kukko 20/10- B -  Extraction hook 250 mm

–  Remove the bearing carrier -A- with the support for the reverse shaft -B-.

Pulling off 5th gear pinion together with inner ring/needle bearing -C- for 2nd gear, thrust washer “S6”-D- and roller bearing -E-. A -  Two-arm extractor, e.g. -Kukko 20/10- B -  Extraction hook 250 mm

Pull off the 6th gear pinion. A -  Two-arm extractor, e.g. -Kukko 20/10- B -  Extraction hook 250 mm   Note t  Position the extraction hooks-B- in the round slot of the gear pinion. t  On certain gearboxes, the 3rd through 6th gear pinions can have sliding seat (no press fit) on the secondary shaft. Here the gear pinions can be removed by hand.

t  Due to the ratio of the 6th gear, the 6th gear -3- pinion may touch -arrow B- the 5th/6th gear sliding gear -2- when pulling off. t  In this case, the gearshift fork -2- with sliding sleeve must be shifted -arrow A- to the 5th gear sliding gear -1-. Then draw out the 6th gear pinion -3- through the running gearing of the 5th gear sliding gear -1--arrow C-, to do so slightly pull the gearshift fork -2- off the sliding sleeve.

Pull off the 3rd gear pinion.   Note When pulling off the gear pinion, draw the input shaft -A- with the 3rd/4th and 5th/6th gearshift forks out of the gearbox housing -direction of arrow-.

Pull off the 4th gear pinion -A-.

–  Remove adjusting washer (s) “S5”-arrow- from secondary shaft, note thickness.   Note Before the secondary shaft is removed, remove the differential from the gearbox housing → Chapter. Then turn the secondary shaft by hand, in order to hear possible running noises of the double angular ball bearing. When turning the installed secondary shaft, the bearing must not “hook” or “run rough”.

–  Release screws -arrows- and remove retaining plate -A- with adjusting washer “S4” located underneath.

–  Carefully pull out secondary shaft -1- from the hole of the gearbox housing -2-. The outer rings -3- and -4- of the double angular ball bearing must not be pulled apart from each other, otherwise the seal -6- of the double angular ball bearing can be damaged by the secondary shaft head -5-. In this case, the double angular ball bearing must be replaced.