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Skoda Workshop Service and Repair Manuals

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Fabia Mk1

General Repair Information
General Repair Information
To carry out gearbox repairs successfully and correctly, scrupulous care and cleanliness, as well as the proper tools, are essential requirements. Obviously, the generally valid basic safety rules apply to repair work.
Below is a summary of the general instructions to be applied to individual repair operations (also given elsewhere at various parts of the workshop manual). They apply to this workshop manual.
Contact corrosion!
t  The gearbox housing is made out of magnesium.
t  Bolts and other attachments that come into direct contact with the gearbox can have varying finishes depending on whether the gearbox housing is of magnesium.
t  The use of substitute components causes contact corrosion (screws, nuts, washers ...). This will result in damage to the gearbox housing.
t  If you have any doubts about re-using parts, always use new parts in accordance with → Electronic Catalogue of Original Parts.
Gearbox
t  When installing, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When replacing the gearbox, pour in gear oil up to lower edge of filler hole.
t  Capacity and specification → Chapter.
Sealant
t  Thoroughly clean the contact surfaces of the housing before applying the silicone sealant.
t  Apply sealant AMV 188 200 03 evenly and not too thick.
O-rings, gasket rings, 0-rings, gaskets
t  Always replace O-rings, gasket rings, O-rings and gaskets → Electronic Catalogue of Original Parts.
t  After removing gaskets, check the contact surface in the housing or shaft for burrs or damage which occured during the assembly.
   
t  Radial shaft seals - before mounting lightly oil at outside diameter and fill half the space between the sealing lips -arrow- with with sealing grease G 052 128 A1.
t  The open side of the sealing rings is turned towards the fluid to be sealed.
t  Press in new gasket ring in such a way that the sealing lip is not located on the same point as the sealing lip of the old gasket ring (use tolerance for insertion depth).
t  Before inserting lightly oil the O-rings, in order to prevent the rings being squashed during installation.
t  Inspect the oil level after replacing the gaskets and gasket rings.
Locking elements
t  Replace circlips.
t  Do not over-tension the circlips.
t  Circlips must be positioned in the base of the groove.
  S00-0264
t  Replace roll pins. Fitting position: Slot longitudinally to power flow -arrow-.
Bolts, nuts
t  Slacken the bolts and nuts against the tightening sequence.
t  Slacken and tighten nuts and bolts for attaching covers and housings without tightening sequence diagonally across in stages.
t  Replace the self-locking screws and nuts.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Clean all threaded holes into which self-locking screws or screws with locking agent are inserted (using e.g. a thread tap). Otherwise there is a risk that the bolts will shear at the next disassembling.
t  It is important to ensure at all bolted connections that the contact surfaces as well as the nuts and bolts are waxed only after being installed, should this be necessary.
Bearings
t  N ew taper roller bearings are fitted as supplied and do not require any additional lubrication.
t  Insert moist all bearings (except taper roller bearings) in the gearbox with gear oil.
t  Before installing, heat the inner rings of the tapered-roller bearing to approx. 100°C., when installing press in axial and play-free up to the stop.
t  Do not mix up the outer and inner races of bearings of the same size.
t  Always jointly replace tapered-roller bearings on the same shaft and use products of the same manufacturer.
t  Always position needle bearing with the lettered side (thicker end) towards the drift pin.
Shims
t  Gauge shims at several points with a micrometer. Different tolerances allow to select the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only shims which are in perfect condition.
Synchronizer rings
t  These are not interchangeable. If re-using, allocate synchronizer rings to the same gear.
t  Inspect for wear, and replace if necessary.
t  Insert with some gearbox fluid.
Gears
t  Clean and heat on a heating plate to max. 100°C before pressing on.
t  Temperature can be checked with a temperature measuring instrument.
Sliding gears
t  Inspect wheels 1st to 6th gear for small axial play or clearance after installation.
Clutch control
t  Do not tilt the clutch pressure plate, release or tighten in small stages crosswise
t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch bell as well as the flywheel and the engine on the side of the gearbox.
  S00-0262

Clutch, control > < Overview of Transmission System