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Skoda Workshop Service and Repair Manuals

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Octavia 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.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here.
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 the lower edge of the filler hole.
t  Capacities and specifications → Chapter.
Gaskets, seals
t  Thoroughly clean sealing surfaces and apply sealant -THREE BOND 1104-.
t  Apply sealant evenly - not too thickly.
t  Replace O-rings → Electronic Catalogue of Original Parts.
Radial shaft seals:
Before installing:
   
Lightly oil the outer diameter and pack the space between the seal lips -arrow- with sealing grease.
After installing:
t  Check gear oil level, if necessary pour in up to lower edge of filler hole, specification → Chapter.
Circlips
t  Replace circlips → Electronic Catalogue of Original Parts.
t  Do not over-tension the circlips.
t  Circlips must be positioned in the base of the groove.
  N32-0001
t  Replace tensioning sleeves → Electronic Catalogue of Original Parts. Fitting location: slot longitudinally to power flow.
Screws, nuts
t  Slacken and tighten nuts and bolts for attaching covers and housings diagonally across.
t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across in stages.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Always replace the self-locking screws and nuts → Electronic Catalogue of Original Parts.
Bearings
t  Fit all bearings to the gearbox with some gearbox fluid.
t  Jointly replace tapered-roller bearings on the same shaft → Electronic Catalogue of Original Parts. If possible use bearings of the same manufacturer.
t  Heat inner races to about 100 °C for installing.
t  Do not mix up the outer and inner races of bearings of the same size! Bearings are paired.
t  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 measure the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only adjusting washers 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, replace if necessary → Electronic Catalogue of Original Parts.
t  Insert with some gearbox fluid.
Pinions
t  Clean and heat with induction heater unit -VAS 6414- to approx. 100°C before pressing on.
  V34-1515

Clutch, control > < Overview of Transmission System