Skoda Workshop Service and Repair Manuals

Disassembling and assembling the output shaft Special tools and workshop equipment required t  Drift -MP1-178- t  Ejector -MP1-502- t  Drift -MP3-403 (VW 295)- t  Pressure washer -MP3-460 (VW 512)- t  Pipe section -MP3-414 (VW 516)- t  Pressure plate -MP3-407 (VW 402)- t  Interior extractor -Kukko 21/6- t  Separating device -Kukko 17/2- t  Countersupport -Kukko 22/2-

t	When installing new pinions or a new output shaft observe the technical data → Chapter.

t	Replace both tapered-roller bearings together.

t	Do not over-tension the circlips. Always replace damaged or over-tensioned circlips.

t	If the clutch housing, output shaft (drive train) or tapered-roller bearing is replaced, it is necessary to adjust the output shaft → Chapter.

1 -	Cover for gearbox housing

2 -	Circlip for 5th gear pinion

3 -	Thrust washer

4 -	5th gear pinion

q	removing and installing → Chapter

5 -	Gearbox housing

6 -	Needle bearing

q	removing and installing → Chapter

7 -	Circlip for 4th gear pinion

8 -	4th gear pinion

q	Fitting position → Chapter

9 -	Circlip for 3rd gear pinion

q	Determining thickness again → Chapter

10 -	3rd gear pinion

q	Fitting position → Chapter

q	Set axial play → Chapter

11 -	2nd gear sliding gear

12 -	Needle bearing for 2nd gear sliding gear

q	Pull off inner ring → Chapter

q	Press on inner ring → Chapter

13 -	2nd gear synchronizer ring

q	check for wear → Fig.

14 -	Sliding sleeve with 1st and 2nd gear synchronizer body

q	Assembling sliding sleeve/synchronizer body → Fig. and → Fig.

q	removing and installing → Chapter

15 -	1st gear synchronizer ring

q	check for wear → Fig.

q	Identification → Fig.

16 -	1st gear sliding gear

17 -

Spring

18 -	Sliding sleeve

19 -	Synchronizer body

20 -

Arresters

q

3 pieces

21 -	Needle bearing

q	for 1st gear

22 -	Thrust washer

q	Fitting position → Chapter

23 -	Clutch housing

24 -	Adjusting washer

q	for output shaft

q	Setting overview → Chapter

25 -	Outer ring/tapered-roller bearing small

q	removing → Fig.

q	installing → Fig.

26 -	Inner ring/tapered-roller bearing small

q	pressing off → Fig.

q	pressing on → Fig.

27 -	Output shaft

q	is paired with the gear pinion of the final drive, when replacing they must both be replaced

q	adjust → Chapter

28 -	Inner ring/tapered-roller bearing large

q	pressing off → Fig.

q	pressing on → Fig.

29 -	Bearing support

q	with outer ring/tapered-roller bearing large and stop for reverse gear

q	Always replace outer ring together with tapered-roller bearing large and bearing support

30 -	25 Nm and torque a further 90°

Check 1st and 2nd gear snychronizer 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
1st and 2nd gear	1.1…1.7 mm	0.5 mm

Identification of the 1st gear synchronizer ring Identification: every 3 x 1 tooth missing -arrow-. This synchronizer ring must only be installed on the 1st gear.

Assemble sliding sleeve with synchronizer body for 1st and 2nd gear Fitting position of synchronizer body: The groove marking on the front side -arrow- points to the outer serration of the sliding sleeve. –  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/synchronizer body for 1st and 2nd gear –  Insert arresters and mount springs with 120° offset. The angled end of the spring must grip into the hollow arrester.

Removing outer ring/tapered-roller bearing small A -  Interior extractor 37...46 mm, e.g. -Kukko 21/6- B -  Countersupport, e.g. -Kukko 22/2-

Pressing in small outer ring/tapered-roller bearing

Press off small inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2-   Note The inner ring can also be removed with the tapered-roller bearing extractor -V.A.G 1582- and the gripper -V.A.G 1582/5-.

Pressing off large inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2-   Note The inner ring can also be removed with the tapered-roller bearing extractor -V.A.G 1582- and the gripper -V.A.G 1582/7-.

Heat inner rings for small and large tapered-roller bearings to approx. 100°C, place in position and press down.