Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft Special tools and workshop equipment required t  Pressure plate -MP 3-406- t  Thrust piece -MP 3-408- t  Pressure plate - MP 3-411- t  Thrust washer -MP 3-413- t  Thrust piece -MP 3-423- t  Thrust piece -MP 3-448- t  Pipe section -MP 3-451- t  Thrust washer -MP 3-455- t  Thrust washer -MP 3-456- t  Pipe section -MP 3-4013- t  Separating device, e.g. -Kukko 17/1-   Note t  When installing new pinions observe the technical data → Chapter. t  If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be reset. Setting overview → Chapter. t  Replace bearings jointly.

1 -	Clutch housing

2 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	installing → Fig.

3 -	Inner ring/tapered-roller bearing

q	pressing off → Fig.

q	installing → Fig.

4 -	Drive shaft

q	adjust → Chapter

5 -	3rd gear pinion

q	Collar points to the 4th gear

q	pressing off → Fig.

q	pressing on → Fig.

6 -

Circlip

q	always replace → Electronic Catalogue of Original Parts

7 -	4th gear pinion

q	pressing off with inner ring/tapered-roller bearing and bushing → Fig.

q	pressing on → Fig.

q	Collar points to the 3rd gear

8 -	Inner ring/tapered-roller bearing

q	press off with 4th gearwheel and bushing → Fig.

q	pressing on → Fig.

9 -	Thrust washer

10 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	installing → Fig.

11 -	Adjusting washer

q	Determine thickness → Chapter

12 -	Gearbox housing

13 -

Bushing

q	for needle bearing

q	press off with 4th gearwheel and inner ring/tapered-roller bearing → Fig.

q	pressing on → Fig.

q	insert thrust washer Pos. 9 before assembly

14 -	Needle bearing

15 -	5th gear sliding gear

q	removing and installing → Chapter

16 -	5th gear synchronizer ring

q	with integrated arresters → Chapter

q	check for wear → Chapter

17 -

Spring

q	Fitting position → Fig.

q	on gearboxes as of manufacturing date 10.04 the spring was changed → Fig.

q	Fitting position → Fig.

18 -	Arresters (3 pieces)

q	Fitting position → Fig.

q	on gearboxes as of manufacturing date 03.01 are installed the arresters, which are hollow inside

19 -	5th gear synchronizer body

q	removing and installing → Chapter

20 -	5th gear sliding sleeve

q	removing and installing → Chapter

21 -	Disc spring

q	Fitting position → Chapter

22 -

80 Nm

q	holds disc spring in position with sleeve socket on screw head → Chapter

q	always replace → Electronic Catalogue of Original Parts

Pressing out outer ring/tapered-roller bearing

Pressing on outer ring/tapered-roller bearing

Pressing out inner ring/tapered-roller bearing A -  Separating device, e.g. -Kukko 17/1-

Pressing on inner ring/tapered-roller bearing

Pressing off 4th gearwheel with tapered-roller bearing and bushing

Pressing out 3rd gearwheel

Pressing on 3rd gear pinion

Pressing on 4th gear pinion Collar points to the 3rd gear

Pressing on inner ring/tapered-roller bearing

Pressing on bushing for needle bearing

Pressing out outer ring/tapered-roller bearing

Pressing on outer ring/tapered-roller bearing –  After setting the drive shaft insert with adjusting washer.

5th gear synchronizer ring 1 -  Springs for arresters 2 -  Sliding sleeve with 3 recesses -arrows A- for the arresters -Pos. 4- 3 -  Synchronizer body 4 -  Arresters for synchronizer body    Fitting position: The leg -arrow B- points to the sharp teeth of the sliding sleeve -Pos. 2-.

Assembling sliding sleeve/5th gear synchronizer body –  Slide the sliding sleeve over the synchronizer body. The sharp teeth -A- of the sliding sleeve and the collar -B- of the synchronizer body point in the same direction. The recesses for the arresters in the sliding sleeve and the synchronizer body must be positioned above one another → Fig. –  Insert arresters (Fitting location: → Fig.). –  Mount the springs with 120° offset under the shoulder -C-. The angled ends of the spring must be located before the arresters -arrows-.

Alteration to the spring for 5th gear synchronisation as of manufacturing date 10.04 Ends of the springs -A- are angled as of the above-mentioned date. The changed springs are mounted on both sides and can be mounted on previous gearboxes only with the inner hollow arresters.

Fitting position of springs as of manufacturing date 10.04 Mount the springs with 120° offset. The angled springs end -A- must engage into the hollow arrester. The spring must be located under the shoulder -B- of the arresters. The angled end always points away from the synchronizer body -direction of arrow-.