Skoda Workshop Service and Repair Manuals

Disassembling and assembling the differential Special tools and workshop equipment required t  Pressure plate -MP 3-406- t  Thrust washer -MP 3-407- t  Thrust piece -MP 3-408- t  Drive bushing -MP 3-427- t  Thrust piece -MP 3-448- t  Pressure plate - MP 3-459- t  Thrust plate -MP 3-464- t  Thrust plate -MP 3-467- t  Pressure plate - MP 3-468- t  Drift -MP 3-510- t  Bushing -MP 3-474- t  Interior extractor, e.g. -Kukko 21/7- t  Countersupport, e.g. -Kukko 22/2 - t  Sealant -AMV 188 200 03-

t	Before installing heat the inner ring of the tapered-roller bearing to 100°C.

t	Replace both tapered-roller bearings together.

t	When replacing the tapered-roller bearing of the differential housing, gearbox housing or clutch housing adjust the differential → Chapter

t	Pos. 2 to 6 only applies for service.

1 -	Gearbox housing

2 -

Screw

3 -	Differential housing

q	screw to pinion for final drive

4 -	Pinion for final drive

q	series riveted

q	screw → Fig.

q	heat to 100 °C before fitting

q	pressing off → Fig.

q	Fitting position → Fig.

q	place on the differential housing → Fig.

q	is paired with the output shaft, replace together

5 -

Shim

6 -	Nut, 70 Nm

7 -	Adjusting washer

q	for differential

q	Determine thickness → Chapter

8 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

9 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

10 -	Differential housing

q	with riveted pinion for final drive

q	when replacing the final drive pinion bore out the rivet heads → Fig.

q	Secure pinion for final drive → Fig.

11 -	Drive wheel for speedometer

q	before pressing on the inner ring place it on the differential gear housing up to the stop

12 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

13 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	installing → Fig.

14 -	Clutch housing

15 -

Bushing

q	for support of gasket ring Pos. 16

q	removing and installing → Chapter

16 -	Gasket ring

q	left - replace with installed gearbox → Chapter

q	right - replace with installed gearbox → Chapter

17 -	Bushing and gasket ring, single version

q	replace damaged gasket ring with bushing → Chapter

q	Difference → Chapter

18 -

25 Nm

q	screw to threaded connector Pos. 26 to attach the flange shaft

19 -	Flange shaft

q	removing and installing → Chapter

20 -	Pressure spring for flange shaft

q	fitted behind flange shafts

21 -	Thrust washer

q	Fitting position: flange to pressure spring, leg to conical ring

q	Fitting position of the changed thrust washer → Fig.

22 -	Conical ring

q	with slots for thrust washer catch

q	Fitting position: Cone towards differential housing

23 -	Retaining clip

q	holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed

24 -	Stop disc compound

q	insert with gear oil

25 -	Differential bevel gear large

q	installing → Fig.

26 -	Threaded part

q	installing → Fig.

27 -	Differential bevel gear shaft

q	drive out with drift -MP 3-510-

q	installing → Fig.

28 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	removing and installing → Fig.

29 -	Differential bevel gear small

q	installing → Fig.

30 -	Differential bevel gear large

q	installing → Fig.

Press outer ring/tapered-roller bearing out of clutch housing –  First remove support bushing for sealing ring/flange shaft.

Press outer ring/tapered-roller bearing into the clutch housing No adjusting washer is fitted at the side of the clutch housing.

Removing inner ring/tapered-roller bearing –  Before fitting the extractor position pressure plate -MP 3-467- on the differential housing.   Note Both inner rings/tapered-roller bearings of the differential housing are removed in the same way.

Press on inner rings/tapered-roller bearing   Note The inner rings/tapered-roller bearing for the gearbox housing and clutch housing are pressed on with the same pressure tools.

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

Press outer ring/tapered-roller bearing into the clutch housing –  Position adjusting washer under outside ring. –  Support the gearbox housing with a bushing -MP 3-474- directly below the bearing support.

Bore out rivet heads –  Bore out the rivet heads on the sunken side with a 12 mm drill and drive out rivets with a drift.   Note Clean differential gear before and after drilling, protect tapered-roller bearing from boring swarf.

Pressing off pinion/final drive –  Fit thrust plate -MP 3-467- on the differential gear housing.

Fitting location of the pinion/final drive –  The circular slot -A- points to the screw-on surface of the differential gear housing.

Heat pinion/final drive to approx. 100 °C and install. –  Guide the pinion/final drive suring fitting with screws -A- from the repair kit.

Screw pinion/final drive and differential housing Use new special screws from the repair kit for gearbox 02R → Electronic Catalogue of Original Parts

Removing and installing the tensioning sleeve for differential bevel gear shaft Removing –  Cover inner ring/tapered-roller bearing and drive wheel for speedometer to avoid any possible damage and swarf. –  Drive out tensioning sleeve with a chisel, position the chisel in the circular slot. –  Press out differential bevel gear shaft with a drift -MP 3-510-. Install –  Replace tensioning sleeve and drive into the differential housing up to the stop.

Install the differential bevel gears –  Install stop disc compound with gearbox oil. –  Insert both large differential bevel gears and secure (e.g. with flange shaft). –  Insert both small differential bevel gears with a 180° offset. –  Push in the differential bevel gear shaft -arrow A- up to the first small bevel gear. –  Insert the threaded parts -arrow B- in the large differential bevel gears.    Fitting position: Heel of the differential bevel gear. –  Insert the differential bevel gear shaft up to end position and secure with new tensioning sleeve.

Fitting position of the changed thrust washer If the thrust washer has no pegs -A-, the collar -arrow- points to the pressure spring -B-.