Skoda Workshop Service and Repair Manuals

Disassembling and assembling the output shaft (input shaft) Special tools and workshop equipment required t  Pressure plate -MP3-407 (10-101) - t  Thrust piece -MP3-408 (VW 412)- t  Pressure plate - MP3-411 (VW 454)- t  Thrust piece -MP3-423 (VW407) - t  Two-arm extractor -Kukko 20/10 - t  Hook -Kukko 1-250- t  Countersupport -Kukko 22/2- t  Separating device -Kukko 17/2 - t  Interior extractor -Kukko 21/6 - t  Thrust piece -MP3-448 (VW 408 A)- t  Thrust piece -MP3-449 (VW 409) - t  Alignment rails -MP3-457 (VW 457) - t  Pressure washer -MP3-460 (VW 512)- t  Pipe section -MP3-461 (VW 519)- t  Insertion tool -MP3-466 (32-111) - t  -V.A.G 1582- t  -V.A.G 1582/5- t  Pipe section -MP3-450 (VW 415 A)- t  Thrust ring -MP3-452 (VW 429)- t  Pressure washer -MP3-455 (VW 447 H)-   Note t  When installing new pinions or a new output shaft observe the technical data → Chapter; assignment → Electronic Catalogue of Original Parts. t  Removing and installing output shaft → Chapter. t  Replace both tapered-roller bearings together. t  The gearboxes manufactured as of 08.00 have a modified 1st gear synchronisation.

1 -	Nut, 25 Nm + 90°

q	4 nuts for bearing support

q	always replace

2 -	Clutch housing

3 -	Adjusting washer

q	Determining thickness ⇒ - Setting output shaft → Chapter

4 -	Outer ring/tapered-roller bearing small

q	removing → Fig.

q	pressing on → Fig.

5 -	Inner ring/tapered-roller bearing small

q	remove → Fig.

q	pressing on → Fig.

6 -	Output shaft

q	is paired with the gear pinion of the final drive, replace together

q	adjust → Chapter

7 -	Inner ring/tapered-roller bearing large

q	remove → Fig.

q	pressing on → Fig.

8 -	Gasket ring

q	Insert gasket rings (4 pieces) on the bearing support screws

9 -	Bearing support

q	with outer ring/tapered-roller bearing large and screws

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

10 -	Thrust washer

q	Heel of thrust washer points to tapered-roller bearing

11 -	1st gear sliding gear

12 -	Needle bearing

q

1st gear

q	Dimensions 38 x 43 x 25

13 -	1st gear synchronizer ring

q	for gearbox ? 08.00

q	check for wear → Fig.

q	Identification → Fig.

14 -	Inner ring for 1st gear

q	for gearbox 08.00 ?

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

15 -	Outer ring for 1st gear

q	for gearbox 08.00 ?

q	fit on inner ring (⇒ Pos. 14), fitting position → Fig.

q	replace if there are any traces of scoring or of friction

16 -	1st gear synchronizer ring

q	for gearbox 08.00 ?

q	Identification → Fig.

q	check for wear → Fig.

q	Fitting position → Fig.

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

q	after removing the circlip (⇒ Pos. 18) pull over bearing support → Fig.

q	disassembling → Fig.

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

q	Fitting position ? 08.00 → Fig.

q	Fitting position 08.00 ? → Fig.

q	pressing on → Fig.

18 -

Circlip

19 -	2nd gear synchronizer ring

q	Identification ? 08.00 → Fig.

q	Identification 08.00 ? → Fig.

q	check for wear → Fig.

q	insert in such a way that the recesses lock into the arresters of the synchronizer body ⇒ Pos. 17

20 -	Outer ring for 2nd gear

q	fit into synchronizer ring (⇒ Pos. 19), fitting position → Fig.

q	replace if there are any traces of scoring or of friction

21 -	Inner ring of 2nd gear

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

22 -	2nd gear sliding gear

q	Fitting position → Fig.

23 -	Needle bearing

q

2nd gear

q	Dimensions 35 x 40 x 23.8

24 -	Thrust washer

q	Dimensions 30.8°x°52 x°3.5

25 -	Bushing for 3rd gear needle bearing

q	press off with 2nd gear sliding gear → Fig.

q	pressing on → Fig.

q	Dimensions 30.6 x 35 x 25.85

26 -	Needle bearing

q

3rd gear

q	Dimensions 35 x 39.6 x 25.5

27 -	3rd gear sliding gear

28 -	3rd gear synchronizer ring

q	check for wear → Fig.

29 -	Sliding sleeve with 3rd and 4th gear synchronizer body

q	press off together with 2nd gear (⇒ Pos. 22) and 3rd gear (⇒ Pos. 27) sliding gear → Fig.

q	disassembling → Fig.

q	Fitting position sliding sleeve/synchronizer body → Fig.

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

q	pressing on → Fig.

30 -

Bushing

q	for needle bearing

q	press off together with sliding sleeve and 3rd and 4th gear synchronizer body (⇒ Pos. 29) → Fig.

q	pressing on → Fig.

q	Dimensions 29 x 35 x 24.1

31 -	Needle bearing

q

4th gear

q	Dimensions 35 x 40 x 23.8

32 -	4th gear synchronizer ring

q	check for wear → Fig.

33 -	4th gear sliding gear

34 -	Thrust washer

q	Dimensions 29,2 x 49 x 2,5

35 -	Needle bearing

q	for output shaft

q	removing and installing → Chapter

36 -	Gearbox housing

37 -

Bushing

q	for needle bearing of output shaft

q	pressing off → Fig.

q	pressing on → Fig.

q	Dimensions 29 x 34 x 18.15

38 -	5th gear sliding gear

q	removing and installing → Chapter

39 -	Disc spring

q	Fitting position → Chapter

40 -	80 Nm + torque a further 90°

q	holds the disc spring in position

q	always replace

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

Extracting small inner ring/tapered-roller bearing -A- Soft vice-protective jaws. –  Position hook on bearing rollers and pull off inner ring.

Press in small inner ring/tapered-roller bearing

Pressing off synchronizer body, sliding sleeve, 2nd, 3rd and 4th gear sliding gear with sleeve for needle bearing -A- Separating device 22 ... 115 mm, e.g. -Kukko 17/2- -B- Screw, e.g. M10 –  Position separating device under 2nd gear (⇒ Pos. 22) sliding gear and press off.   Note Support the separating device in such a way that the 1st and 2nd gear sliding sleeve is not drawn off.

Remove sliding sleeve with synchronizer body via bearing support -A- Screw M10 x 20 –  Remove circlip (⇒ Pos. 18). –  Remove together with 1st gear sliding gear with sliding sleeve with synchronizer body for 1st and 2nd gear.

Pulling off large inner ring/tapered-roller bearing -A- Soft protective jaws –  Before fitting the extractor insert screw M10 x 20 in the output shaft bore.

Pressing on large inner ring/tapered-roller bearing -A- Thrust washer –  Insert thrust washer before pressing in the inner ring. The shoulder is located on the side of the inner ring.

Check 1st gear synchronizer ring ? 08.00, 3rd and 4th gear for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance “a” with a feeler gauge.

		Fitting dimension	Wear limit
	Clearance -a-	1,0 ... 1.7 mm	0.5 mm

Disassembling and assembling the sliding sleeve and 1st and 2nd gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arresters for synchronizer body –  Slide the sliding sleeve over the synchronizer body. For gearbox ? 08.00 The wide collar of the synchronizer body (-arrow A-) and the outer serration of teh sliding sleeve (-arrow B-) point in opposite directions after assembly. The recesses for the arresters on the synchronizer body and the sliding sleeve must be in line with each other. For gearbox 08.00 ? The chamfered edge ( → Fig.) and the outer serration of the sliding sleeve (-arrow B-) point in one direction after assembly. The recesses for the arresters on the synchronizer body and the sliding sleeve must be in line with each other.

Assembling the sliding sleeve and 1st and 2nd gear synchronizer body l  The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and mount springs with 120° offset. The angled ends of the springs must grip into the recess in the arrester.

Fitting position of the sliding sleeve and 1st and 2nd gear synchronizer body ? 08.00 The teeth of the sliding sleeve (-arrow 1-) point towards the serration for the 3rd/4th gear synchronizer body -A-. The wide collar of the synchronizer body (-arrow 2-) points to the 1st gear -B-.

Press on the sliding sleeve and 1st and 2nd gear synchronizer body   Note Before pressing on insert the synchronizer ring for the 1st gear on the 1st gear sliding gear.

Identification of the 1st and 2nd gear synchronizer rings ? 08.00 t  1st gear - 3 synchronizer ring on the half height of the flattened tooth (-arrow-) t  1st gear - 3 synchronizer ring on the half height of the flattened tooth (-arrow-) Only the synchronizer ring with 2 flattened teeth are offered as spare part for the 2nd gear.

Difference between the 1st and 2nd gear synchronizer rings For gearbox ? 08.00 t  1st gear synchronizer ring - no recess t  2nd gear synchronizer ring - 3 recess (-arrows-) For gearbox 08.00 ? t  1st and 2nd gear synchronizer rings are identical; identification → Fig.

Check 1st and 2nd gear inner ring for wear –  Press the inner ring on the cone of the sliding gear and measure clearance “a” with a feeler gauge.

		Fitting dimension	Wear limit
	Clearance -a-	0,75 ... 1.25 mm	0.3 mm

Check 1st and 2nd gear snychronizer rings for wear –  Press the synchronizer ring (outer ring and inner ring) on the cone of the sliding gear and measure clearance “a” with a feeler gauge.

		Fitting dimension	Wear limit
	Clearance -a-	1,2 ... 1.8 mm	0.5 mm

Outer ring fitting location The pegs (-arrows-) point towards the 1st gear -A-.

Fitting location inner ring -A- The pegs (-arrow 1-) lock into the recesses (-arrow 2-) of the synchronizer ring -B-.

Fitting position 2nd gear sliding gear The higher collar -A- points towards the 1st gear -B-. The recesses in the collar (-arrows-) lock into the pegs of the outer ring (-arrow- → Fig.).

Insert thrust washer and press on bushing for 3rd gear needle bearing. –  Install needle bearing, sliding gear and 3rd gear synchronizer ring.

Identification of the 3rd gear synchronizer ring Identification: every 3 x 1 tooth missing -arrow-

Disassembling and assembling the sliding sleeve and 3rd and 4th gear synchronizer body 1 -  Spring 4 -  Arresters for synchronizer body 3 -  Sliding sleeve 4 -  Synchronizer body –  Slide the sliding sleeve over the synchronizer body. The recesses for the arresters on the synchronizer body and the sliding sleeve must be in line with each other.

Assembling the sliding sleeve and 3rd and 4th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert arresters and mount springs with 120° offset. The angled ends of the springs must grip into the recess in the arrester.

Fitting position of the sliding sleeve and 3rd and 4th gear synchronizer body chamfered edge (-arrow-) points towards the 4th gear.

Press on the synchronizer body and the 3rd and 4th gear sliding sleeve

Pressing on bushing for 4th gear needle bearing –  Install needle bearing, 4th gear sliding gear and synchronizer ring. –  Place thrust washer over 4th gear sliding gear.

Pressing on bushing for needle bearing/output shaft -A-

Fitting position of the outer ring, inner ring and 1st gear synchronizer ring –  Position the inner ring -A- on the 1st gear sliding gear. The angled lands -arrow 1- point towards the outer ring -B-. –  Position the outer ring -B-. Lock the lands -arrows 2- in the recesses -arrows 3- of the sliding gear. –  Position the synchronizer ring -C-. Lock the recesses -arrows 4- in the lands -arrows 1- of the inner ring -A-.

Identification of the 1st and 2nd gear synchronizer rings 08.00 ? Identification: every 3 x 2 teeth missing -arrows-

Fitting position of the sliding sleeve and 1st and 2nd gear synchronizer body 08.00 ? The chamfered edge -arrow A- and the outer serration of the sliding sleeve -arrow B- point to 2nd gear sliding gear.