Skoda Workshop Service and Repair Manuals

Removing –  Position catch pan underneath.

–  Drain gear oil, to this end unscrew oil drain plug -arrow-.

–  Secure gearbox to the assembly stand -arrows-. –  Removing the release lever, release bearing and guide bushing → Chapter. –  Unscrew the cover -1- for the gearbox housing.

Remove shift fork and 5th gear sliding sleeve as follows: –  Put shift fork -1- in Neutral position. –  Release screw -2- for bearing pins. –  Remove bearing pins -arrows A-. –  Guide shift fork out of shift rail -arrow B-. –  Remove spring -3-. –  Carefully pull off sliding sleeve -4-, and also remove locking elements. –  Put the sliding sleeve without shift fork back onto the synchronizer body.

–  Unscrew screws -A- for synchronizer body and 5th gear pinion. To this end engage the 5th gear -arrow 1- and 1st gear -arrows 2 and 3-. –  The input and output shafts are blocked after introducing the two gears, the synchronizer body and pinion cannot rotate. Now it is possible to release the two bolts. –  Pull off 5th gear synchronizer, sliding sleeve and arresters with extractor -T10309-.

–  Insert device -T10309/1- between 5th gear pinion -A- and bearings of the shift fork for 5th gear -B-. Device -T10309/1- must be positioned under the synchronizer ring and if necessary pressed into the end position. –  Turn device -T10309/1--in direction of arrow-.

–  Fit the extension onto the device -T10309/1- with thread -T10309/3-. –  Position the other device -T10309/1- and fit pipe -T10309/2- above both devices. –  After drawing together, check if the synchronizer body is not damaged. –  Remove 5th gear pinion together with needle bearing of the drive shaft.

–  Remove gearwheel for 5th gear.   Note t  When pulling off the gear pinion make sure the hooks do not bend outwards, if necessary tighten screw -arrow-. t  5. Check 5th gear for damage after removing. A -  Two-arm extractor e. g. -Kukko 20/10- with hook -Matra V/170- B -  Hexagon screw M10 x 20 Mounting sequence: t  Set up two-arm extractor and centre by turning the screw -arrow-. t  If necessary heat pinion with hot-air blower (e.g. -V.A.G 1416-) and remove with two-arm extractor.

–  Remove the left flange shaft. Use drift to secure against turning and unscrew conical screw -arrow-.

–  Remove both screws -arrows- for support/reverse shaft. –  Remove the gearshift shaft with cover. Put the gearshift shaft into Neutral.

–  Subsequently unscrew screws -arrows- and remove the gearshift shaft from the gearbox housing by levering off the gearshift cover.

–  Remove screws -arrows- from the cap -A- and the bearing pins -B- at the bottom of the gearbox.

–  Carefully remove the cap -A- with driver -MP 1-304 - and hammer -B-.

–  Remove bearing pins -A- on the top side of the gearbox and fixing screws -B- for the gearbox housing on the clutch housing near the differential gear.

–  Release screws -A-, that serve to secure the gearbox housing from the clutch housing.   Note Do not release nuts -B- for the output shaft bearing support.

–  Carefully release the gearbox housing from the projecting housing lands -arrows- and make sure the sealing surfaces are not damaged in the process.

–  Remove shift forks -A- together with shift rails. –  Unscrew shift mechanism/reverse gear -B-.

–  Release nuts -B- for the bearing support/output shaft.

–  Successively remove the reverse gear -A-, drive shaft -B- and output shaft -C- from the clutch housing. –  Remove right flange shaft and take out differential gear.