Skoda Workshop Service and Repair Manuals

Setting output shaft gears 1 through 4 Special tools and workshop equipment required t  Thrust piece -MP3-423 (VW 407)- t  Universal dial gauge holder -MP3-447 (VW 387)- t  Pressure plate -MP6-415 (3260)- t  Retaining plate -T30027 (VW 801)- t  Pressure plate -T30042 (2050)- t  Assembly device -T30069 (VW 792)- t  Interior extractor e.g. -Kukko 21/7- t  Countersupport e.g. -Kukko 22/2 - t  Torque wrench t  Dial gauge (Determine adjusting washer for output shaft) The output shaft must be re-set when the following components are replaced: t  Gearbox housing t  Clutch housing t  Output shaft gears 1 through 4 t  Tapered-roller bearing for output shaft Setting overview → Chapter. Requirements: l  Sealing surfaces of clutch and gearbox housing must be removed of sealant residues. l  During the measurement, only install the output shaft to be measured.

–  Press outer ring/tapered-roller bearing with a 1.70 mm thick adjusting washer into the gearbox housing. While doing so support the gearbox housing with a pressure plate -T30042- directly below the bearing support. –  Insert complete output shaft gears 1 through 4 into the clutch housing.

–  Fit on gearbox housing and tighten screws -A- and -B- crosswise with tightening torque → Chapter or → Chapter.

–  Mount the measuring tools and fasten with screw -arrow- to the clutch housing.   Note

The supporting bridge -MP3-425- can also be fitted to the clutch housing -arrow-instead of the assembly device -T30069-. –  Dial gauge (3 mm measuring range) and set to “0” with a 1 mm bias. –  Slacken fixing screws of clutch housing/gearbox housing crosswise, until the screws release the gearbox housing or the output shaft. –  Read off measured value on dial gauge and note (example: 0,14 mm).   Note If no measured value is displayed on the dial gauge when loosening the fixing screws of the clutch housing/gearbox housing, install the adjusting washer 1.95 mm or if necessary the adjusting washer 2.20 mm for the measurement. Determine the adjusting washer The prescribed bearing preload is reached by removing the established measured value (0,14 mm) from the inserted adjusting washer (1.70 mm) and by adding a constant compression value (0.20 mm). Example:

inserted washer	1.70 mm
- measured value	0.14 mm
+ pressure (const. value)	0.20 mm
Thickness of the adjusting washer	1.76 mm

–  Determine thickness of the adjusting washer according to the table → Anchor.

–  Remove the gearbox housing and pull the outer ring/tapered-roller bearing out of the gearbox housing. A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7- –  Remove the inserted adjusting washer (1.70 mm thick) from the gearbox housing. Adjusting washer table

Thickness (mm)	Spare part No.
1,45	084 409 383 AG
1,50	084 409 383 AH
1,55	084 409 383 AJ
1,60	084 409 383 AK
1,65	084 409 383 AL
1,70	084 409 383 AM
1,75	084 409 383 AN
1,80	084 409 383 AP
1,85	084 409 383 AQ
1,90	084 409 383 AR
1,95	084 409 383 AS
2,00	084 409 383 AT
2,05	084 409 383 BA
2,10	084 409 383 BB
2,15	084 409 383 BC
2,20	084 409 383 BD
2,25	084 409 383 BE

Different tolerances allow to select the required thickness for each washer very precisely.

–  Press in outer ring/tapered-roller bearing with the determined adjusting washer (in the example 1.75 mm). While doing so support the gearbox housing with a pressure plate -T30042- directly below the bearing support. Control measurement l  Determined adjusting washer fitted.

–  Mount the measuring tools and fasten with screw -arrow- to the clutch housing.   Note

The supporting bridge -MP3-425- can also be fitted to the clutch housing -arrow-instead of the assembly device -T30069-. –  Dial gauge (3 mm measuring range) and set to “0” with a 1 mm bias. –  Slacken fixing screws of clutch housing/gearbox housing crosswise, until the screws release the gearbox housing or the output shaft. –  The dial gauge must indicate a value of 0.15 mm to 0.25 mm if the adjusting washer has been correctly chosen.