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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
Gearboxes are constructed of aluminium and of magnesium. Distinguishing features of the aluminium gearboxes → Chapter.
t  Gearbox housing and clutch housing are made of the same materials.
t  Bolts and other attachments that come into direct contact with the gearbox can have varying finishes depending on whether the gearbox is made of aluminium or magnesium.
t  The use of substitute components causes contact corrosion. This will result in damage to the gearbox.
t  Bolts and other attachments should have a classification in the → Electronic Catalogue of Original Parts.
t  When installing, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When replacing the gearbox check the gear oil level → Chapter.
t  Capacity and specification → Chapter.
Gaskets, seals
t  Clean contact surfaces thoroughly and apply sealant -AMV 188 200 03-.
t  Apply sealant evenly - 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 → Electronic Catalogue of Original Parts.
Locking elements
t  Do not over-tension the circlips, replace if necessary → Electronic Catalogue of Original Parts.
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-.
Screws, nuts
t  Slacken and tighten nuts and bolts for attaching covers and housings diagonally across in stages.
t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across.
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  Clean all threaded holes into which self-locking screws or screws with locking agent are inserted (using e.g. a thread tap). Otherwise there is a risk that the bolts will shear at the next disassembling.
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  New 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 the inner races of the bearings on a heating plate or with an induction heater unit e.g. -VAS 6414- to approx. 100°C for installing.
t  Do not exchange the outer and inner rings of bearings of the same size - bearings go in pairs.
t  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 grooves -arrow 1- on synchronizer ring -A- or inner ring for flattened parts (grooves are worn).
t  When the intermediate ring -B- is installed, check outer -arrow 2- and inner -arrow 3- contact surface for scoring, blue coloring (caused by overheating) and other damages.
t  Check the cone of the sliding gear for scoring.
t  Insert moist with some gearbox fluid.
Pinions
t  Clean and heat on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 100°C before pressing on.
t  Check fitting position.
Sliding gears
t  Check 1st to 5th gear sliding gears after assembly for low axial play or smooth operation.
Clutch control
t  When removing gearbox, remove slave cylinder without opening the line system.
t  If the slave cylinder with connected hydraulic line is removed, do not depress the clutch pedal. Otherwise the piston is pressed out of the slave cylinder.
t  Do not tilt the clutch pressure plate; release and tighten crosswise in small stages.
t  If the clutch pedal does not return to its initial position after the coupling procedure - clutch pedal in home position - the clutch system must be bled (further measures → Chapter).
t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch bell as well as the flywheel and the engine on the side of the gearbox.
  N35-10107

Clutch, control > < Designation of components and transmission ratio