Skoda Workshop Service and Repair Manuals

Assembling gearbox

–  Insert the differential -1-. –  Insert output shaft 5th/6th and reverse gear output -2- together with reverse gear shift fork, 5th/6th gear -3- and reverse shaft -4-.

–  As shown in the figure take the output shaft gears 1 through 4 -3- with the gear shift rods -5- in the right hand. –  Slightly lift the differential with the left hand. –  At the same time a 2nd mechanic lifts the output shaft 5th/6th gear and reverse gear -2- together with the reverse shaft -4-. –  Now insert the output shaft gears 1 to 4 in the direction of the arrow. The serration of the output shafts and final drive/differential must be in mesh. –  Now place the shafts together with a 2nd mechanic in their bearing assembly.

–  Position the drive shaft in the clutch housing and swivel -direction of arrow-.

–  Position the lock washer -A- into the recess of the clutch housing (outer ring/tapered-roller bearing for drive shaft). –  Tighten new screw to tightening torque → Chapter. –  Fit gearbox housing.

Install the gearshift shaft as follows: –  Put the shift rods into Neutral. –  Insert the gearshift shaft -1-. –  Align the gearshift shaft in such a way that the shift fingers are inserted into the shift rods → Fig.. –  To do so align the bottom bearing -arrow- of the gearshift shaft through the hole for the cap. –  Screw the cap -A- with a screw -2- M8 x 60 mm to the bottom bearing for gearshift shaft -1-.

–  Insert cap -A- manually by alternatively tightening (1/2 turn) the screws -arrows-. –  Unscrew the screw -2- and for this operation screw in the original screw by hand. –  Install gearshift cover -B- for gearshift shaft and tighten the hexagon screws -4- to tightening torque → Chapter. –  Now tighten the hexagon screws for the cap to tightening torque → Chapter. –  Insert locking screw -3- for the sliding-block of the gearshift shaft with locking agent -D 000 600 A2- and tighten to tightening torque → Chapter. –  Install reversing light switch and tighten to tightening torque → Chapter.

–  Install both flange shafts with pressure springs, stop discs and conical rings. –  Install speedometer sender → Chapter.

–  Drive in the gasket ring for the drive shaft. –  Mount slave cylinder with release bearing → Chapter.

–  Insert new O-ring -3- at the connection -1- of the slave cylinder. –  Press on the bleeder -4- at the connection of the slave cylinder until the retaining clip -2- clicks into place. –  For checking pull at bleeder. –  Shift through all gears consecutively. –  Remove gearbox from assembly stand.