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Skoda Workshop Service and Repair Manuals

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Clutch, control > < Designation of components and transmission ratio

Fabia Mk1

General Repair Information
General Repair Information
To carry out gearbox repairs successfully and correctly, scrupulous care and cleanliness, as well as the proper tools, are essential requirements. Obviously, the generally valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here. They apply to this workshop manual.
Gearbox
t  When installing, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When replacing the gearbox, pour in gear oil up to lower edge of filler hole → Chapter.
t  Capacity and specification → Chapter.
Gaskets, seals
t  Clean contact surfaces thoroughly and apply sealant -AMV 188 200 03-.
t  Apply sealant evenly, and not too thickly.
t  Replace O-rings → Electronic Catalogue of Original Parts.
t  Replace radial shaft seals → Electronic Catalogue of Original Parts.
Before installing:
   
Lightly oil the outer diameter and pack half the space between the sealing lips -arrow- with sealing grease -G 052 128 A1-.
After installing:
Check gear oil level, if necessary pour in up to lower edge of filler hole → Chapter, specification → Chapter.
Locking elements
t  Replace circlips → Electronic Catalogue of Original Parts.
t  Do not over-tension the circlips.
t  Circlips must be positioned in the base of the groove.
  N32-0001
t  Replace roll pins. Fitting position: Slot longitudinally to power flow -arrow-.
Bolts, nuts
t  Slacken and tighten nuts and bolts for attaching covers and housings diagonally across.
t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across in stages.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Always replace the self-locking screws and nuts → Electronic Catalogue of Original Parts.
t  It is important to ensure at all bolted connections that the contact surfaces as well as the nuts and bolts are waxed only after being installed, should this be necessary.
Bearings
t  N ew taper roller bearings are fitted as supplied and do not require any additional lubrication.
t  Fit needle bearings to the gearbox with some gearbox fluid.
t  Replace all taper roller bearings belonging to one shaft at the same time. As far as possible use bearings of the same make.
t  Heat inner races to about 100 °C for installing.
t  Do not exchange the outer and inner rings of bearings of the same size - bearings go in pairs.
t  Always position needle bearing with the lettered side (thicker end) towards the drift pin.
Shims
t  Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only shims which are in perfect condition.
Synchronizer rings
t  These are not interchangeable. If re-using, allocate synchronizer rings to the same gear.
t  Inspect for wear, replace if necessary → Electronic Catalogue of Original Parts.
  V34-1515
t  Check slots -arrow 1- on synchronizer ring -A-, or check the inside of the ring for flattened parts (slots worn).
t  When installing the intermediate ring -B-, outer -arrow 2- and inner -arrow 3- check contact surface for grooves, blue coloring (caused by overheating) and other damages.
t  Insert moist with some gearbox fluid.
Gears
t  Clean and heat on a heating plate to approx. 100°C before pressing on.
t  Temperature can be checked with a temperature measuring instrument.
  N35-10107

Clutch, control > < Designation of components and transmission ratio