Skoda Workshop Service and Repair Manuals

Disassembling and assembling output shaft 5th/6th and reverse gear Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-408 (VW 412)- t  Pressure plate -MP3-411 (VW 454)- t  Press-on sleeve -MP3-412 (VW 455)- t  Pipe section -MP3-414 (VW 516)- t  Pressure plate -MP3-431 (3002)- t  Pressure washer -MP3-413 (VW 510)- t  Thrust piece -MP3-423 (VW 407)- t  Thrust piece -MP3-448 (VW 408A)- t  Pipe section -MP3-450 (VW 415A)- t  Pressure plate -MP3-453 (VW 431)- t  Alignment rails -MP3-457 (VW 457)- t  Pipe section -MP3-461 (VW 519)- t  Thrust plate -MP3-467 (40-105)- t  Pressure plate -MP3-4014 (VW 432)- t  Pressure plate -MP6-415 (3260)- t  Retaining plate -T30027 (VW 801)- t  Pressure plate -T30042 (2050)- t  Pipe -T30055 (3296)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/4- t  Gripper -V.A.G 1582/7- t  Separating device, e.g. -Kukko 17/2 - t  Interior extractor e.g. -Kukko 21/7- t  Countersupport e.g. -Kukko 22/2 -

Remove outer ring/tapered-roller bearing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-   Note After pulling out the washer check for damage, if necessary replace.

Press outer ring/tapered-roller bearing into the clutch housing –  Position washer under outside ring. –  Support the clutch housing with a pipe section -MP3-450 - directly below the bearing support.

Removing inner ring/tapered-roller bearing –  First remove the circlip. –  Before fitting the extractor position thrust piece -MP3-453- and pressure plate -MP3-467- on output shaft.

Pressing off 5th and 6th gear synchronizer body/sliding with sliding gear for 6th gear –  First remove the circlip.

Pressing off bushing -A- with reverse gear sliding gear –  First remove the circlip.

Pressing off reverse gear synchronizer body –  First remove the circlip. A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Removing inner ring/tapered-roller bearing –  Before fitting the extractor, position pressure plate -MP3-431- on the output shaft.

Fitting position of reverse gear synchronizer body The stop -arrow A- for the reverse gear sliding sleeve points towards the output shaft serration -arrow B-.

Pressing on reverse gear synchronizer body –  Install circlip.

Pressing on bushing -A- Fitting position: broad collar points towards the reverse gear sliding gear. –  Install circlip.

Check 5th and 6th gear synchronizer ring for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.

Clearance -a-	Fitting dimension	Wear limit
5th and 6th gear	1.0 ... 1.7 mm	0.5 mm

Disassembling and assembling the sliding sleeve and 5th and 6th gear synchronizer body 1 -  Spring 2 -  Arresters 3 -  Sliding sleeve 4 -  Synchronizer body –  Slide the sliding sleeve over the synchronizer body. The recesses for the arresters on the synchronizer body and the sliding sleeve must be positioned above one another.

Assembly of the sliding sleeve/5th and 6th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and mount springs with 120° offset. The angled end of the spring must grip into the hollow arrester.

Press on the sliding sleeve and 5th and 6th gear synchronizer body –  Install circlip.

Pressing on inner ring/tapered-roller bearing –  Determine the circlip → Fig. and install.

Determining the circlip –  Find the thickest 2nd circlip that can be fitted, and mount it. The following circlips are available:

Thickness (mm)	Spare part No.
1,79	02M 311 187 G
1,83	02M 311 187 F
1,86	02M 311 187 E
1,89	02M 311 187 D
1,92	02M 311 187 C
1,95	02M 311 187 B
1,98	02M 311 187 A

Pressing on inner ring/tapered-roller bearing

Remove outer ring/tapered-roller bearing from gearbox housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing –  Support the gearbox housing with a pressure plate -T30042 - directly below the bearing support.