Skoda Workshop Service and Repair Manuals

Assembling gearbox l  A new grooved ball bearing must be pressed onto the drive shaft → Chapter.

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

–  Insert the differential -1-.   Note For further installation of the shafts in the clutch housing a second mechanic is required. –  Take the output shaft gears 1 through 4 -3- with the gear shift rods -4- in the right hand as shown. –  Slightly lift the differential with the left hand. –  At the same time the 2nd mechanic lifts the drive shaft, the output shaft 5th/6th gear and reverse gear -2- together with the reverse shaft. –  Insert the output shaft gears 1 through 4 in -the direction of the arrow-. l  The serrations of the drive shaft, output shafts and final drive/differential must be in mesh. –  Place the shafts and the differential in their bearing assembly.

–  Secure the supporting bridge -MP3-425- for the drive shaft to the clutch housing.   Note To provide a clearer illustration, the clutch housing is shown at an angle of 180°. –  Screw in screw -A- until the drive shaft is lifted slightly. The gearbox housing is modified as of gearbox manufacturing date 10 04 6. A washer is inserted above and below the grooved ball bearing for the drive shaft → Chapter.

Top washer	Outer diameter	78.6 mm
Bottom washer	Outer diameter	85 mm

–  Check gearbox housing as follows:

–  Measure the shoulder above the support for the grooved ball bearing dimension -a-. The shoulder is chamfered deeper for the support of the washer.

Shoulder above the grooved ball bearing	Dimension “a”	Washer
as of gearbox manufacturing date 10 04 6	10.7 mm	yes
up to gearbox manufacturing date 09 04 6	10 mm	no

In the gearbox housing the bearing pedestal for the grooved ball bearing is also modified as of gearbox manufacturing date 10 04 6. The bearing pedestal -arrow- for the grooved ball bearing (Pos. -2- ⇒ fig. N34-10816) is chamfered slightly deeper for the support of the washer (Pos. -1- ⇒ fig. N34-10816) .

As of gearbox manufacturing date 10 04 6 place a washer (outside diameter = 85 mm) -1- onto the grooved ball bearing -2-. –  Heat the gearbox housing with the -Heißluftgebläse- at the bearing assembly for grooved ball bearing/drive shaft to 100 °C for around 10 minutes. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface.

–  Fit gearbox housing and tighten new screws -A-, -B- and -C- to tightening torque → Chapter. Assignment of screws: A -  Screw with captive washer B -  Screw without washer C -  Screw with captive washer

As of gearbox manufacturing date 10 04 6 place a washer -1- (outside diameter = 78.6 mm) above the grooved ball bearing -2-.

–  Install circlip -1- for grooved ball bearing/drive shaft. –  Remove supporting bridge -MP3-425- for drive shaft.

–  In case the serrated sleeve for the gearshift shaft was removed, drive it in with the drift -T10169- up to the stop of the tool. –  Turn the gearbox with the opening for the gearshift shaft in the assembly stand upwards.

–  Insert the gearshift shaft -1- into the bottom bearing -2- and into the gearshift forks -3-. The cap in the illustration is removed for purposes of clear presentation.

–  Press the gearshift shaft -1- against the serrated sleeve -2--direction of arrow- and guide with the shift finger -3- through the gearshift forks up to the stop downwards. l  The gearshift cover -4- must be positioned at the same time parallel to the screw-on surface at the gearbox housing. l  The gearshift shaft must slide easily into the selector movement (upwards and downwards).   Note If the gearshift cover is positioned obliquely to the screw-on surface, the gearshift shaft is not inserted into the bottom bearing.

–  Tighten screws -3- for the cover/gearshift shaft -4- to tightening torque → Chapter. –  Screw in locking screw -1-, at the same time the locking angle -arrow- must be laid out. –  Install reversing light switch -2- and tighten to tightening torque → Chapter.

–  Install both flange shafts with pressure springs, stop discs and conical rings.

–  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.

–  Drive the cap into the gearbox housing as far as the stop of the drift pin -3382-. –  Remove gearbox from assembly stand.