Skoda Workshop Service and Repair Manuals

Repair gearbox housing, up to gearbox manufacturing date 18 05 3 Special tools and workshop equipment required t  Valve stem seal insertion tool -MP1-233 (3365)- t  Pressure spindle -MP3-423 (VW 407)- t  Centering mandrel -MP3-463 (12 - 551)- t  Gearbox mount -MP3-501- t  Pipe section -MP3-4012 (VW 416 B)- t  Assembly stand -MP9-101- t  Retaining plate -T30027 (VW 801)- t  Centering mandrel -T30029 (3176)- t  Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2- t  Interior extractor 23.5...30 mm e.g. -Kukko 21/4- t  Countersupport e.g. -Kukko 22/2-

1 -	Gearbox housing

q	clamp into the assembly stand → Fig.

q	when replacing: set drive shaft, output shafts and differential gear → Chapter

2 -	Sealing ring

q	if present, always replace → Electronic Catalogue of Original Parts

3 -	Oil drain plug

q	pay attention to different versions → Fig.:

t	with internal serration, 45 Nm

t	with hexagon socket, 30 Nm

4 -	Serrated sleeves

q	extracting → Fig.

q	inserting → Fig.

5 -	Oil filler plug

q	pay attention to different versions → Fig.:

t	with internal serration, 45 Nm

t	with hexagon socket, 30 Nm

6 -	Locking bolt

q	locks the gearshift shaft → Chapter when setting the shift mechanism

q	extracting → Fig.

q	inserting → Fig.

7 -

Bushing

q	for selector rods

q	replace after each removal

q	removing → Fig.

q	installing → Fig.

8 -	Needle bushing

q	replace after each removal

q	removing → Fig.

q	installing → Fig.

9 -	Adjusting washer

q	for drive shaft

q	Setting overview → Chapter

10 -	Outer ring/tapered-roller bearing

q	for drive shaft

q	removing and installing → Chapter

q	when replacing: set the drive shaft → Chapter

11 -	Outer ring/tapered-roller bearing

q	for output shaft for 5th/6th gear and reverse gear

q	removing and installing → Chapter

q	when replacing: Set output shaft 5th/6th gear and reverse gear → Chapter

12 -	Adjusting washer

q	for output shaft 5th/6th gear and reverse gear

q	Setting overview → Chapter

13 -	Outer ring/tapered-roller bearing

q	for output shaft gears 1 through 4

q	removing and installing → Chapter

q	when replacing: Set output shaft gears 1 through 4 → Chapter

14 -	Adjusting washer

q	for output shaft gears 1 through 4

q	Setting overview → Chapter

15 -	Outer ring/tapered-roller bearing

q	for differential gear

q	removing and installing → Chapter and/or → Chapter

q	when replacing: Set the differential gear → Chapter

16 -	Adjusting washer

q	for differential gear

q	Setting overview → Chapter

17 -	Sealing ring

q	replace → Chapter

Secure gearbox housing to the assembly stand with screws -arrows-.

Drive out serrated sleeves

drive in serrated sleeve up to stop –  Drive in serrated sleeve up to stop using socket wrench insert -A- SW 13 and plastic hammer.

Drive out locking bolt

Drive in locking bolt -A- up to stop

Remove bushing for gear shift rod A -  Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2 - B -  Countersupport, e.g. -Kukko 22/2-   Note After removing the bushing check for damage, if necessary replace.

Drive in the bushing for shift rod flush

Pull needle bushing for reverse shaft out of the gearbox housing A -  Interior extractor 23.5...30 mm, e.g. -Kukko 21/4- B -  Countersupport, e.g. -Kukko 22/2-   Note The needle bushing is damaged when removed and must always be replaced.

Pressing in needle bushing -A- in the gearbox housing –  During press-in procedure, position the thrust washer -B- of the reverse shaft onto the needle bushing. –  Support the gearbox housing with pipe -MP3-4012- directly below the bearing support.