Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft for gearbox up to gearbox manufacturing date 06.03 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  Pressure washer -MP3-413 (VW 510)- t  Thrust piece -MP3-423 (VW 407)- t  Drift pin -MP3-426 (30-505)- t  Drive bushing -MP3-427 (40-21)- t  Pipe section -MP3-429 (20-10)- t  Pressure plate -MP3-453 (VW 431)- t  Thrust plate -MP3-467 (40-105)- t  Pipe section -MP3-4012 (VW 416B)- t  Pressure plate -MP3-4014 (VW 432)- t  Gearbox mount -MP3-501- t  Washer -MP6-415 (3260)- t  Retaining plate -T30027 (VW 801)- t  Knock-in bushing -T30034 (41-501)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/7- t  Interior extractor 46...58 mm, e.g. -Kukko 21/7- t  Separating device 22...115 mm, e.g. -Kukko 17/2- t  Countersupport, e.g. -Kukko 22/2 -

t	When installing new pinions observe the technical data → Chapter.

t	If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be reset. Setting overview → Chapter.

t	Replace both tapered-roller bearings together.

1 -	Gearbox housing

2 -	Adjusting washer

q	Determine thickness → Chapter

3 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -

Circlip

q	determine → Fig. when replacing the tapered-roller bearing (-Pos. 5-) and the output shaft (-Pos. 8-)

5 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

6 -	5th gear pinion

q	pressing off → Fig.

q	pressing on → Fig.

7 -	3rd/4th and 6th gear pinion

q	pressing off → Fig.

q	pressing on → Fig.

8 -	Drive shaft

q	adjust → Chapter

9 -	Inner ring/tapered-roller bearing

q	pressing off → Fig.

q	pressing on → Fig.

10 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	Fitting position → Fig.

q	installing → Fig.

11 -	Clutch housing

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 washer -MP3-413 - directly below the bearing support.

Removing inner ring/tapered-roller bearing -A- Protective jaws/vice –  First remove the circlip. –  Before fitting the extractor position the pressure plate -MP3-453- and the thrust plate -MP3-467- on the drive shaft.

Pressing out 5th gear pinion A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing out 3rd/4th and 6th gear pinion

Pressing out inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing on 3rd/4th and 6th gear pinion –  Heat pinion to approx. 100 °C. –  Press on the gear pinion forcefully so that the heat is not transfered immediately onto the drive shaft.

Pressing on inner ring/tapered-roller bearing

Pressing on 5th gear pinion

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

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

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

Fitting position of outer ring/tapered-roller bearing in clutch housing Recesses for the lock washer ( → Fig.) at outer ring/tapered-roller bearing -arrow A- and clutch housing -arrow B- must be positioned above one another.

Pressing on outer ring/tapered-roller bearing –  After the pressing in procedure, check if the lock washer -A- can be inserted into the recess.