Skoda Workshop Service and Repair Manuals

Disassembling and assembling output shaft gears 1 through 4 Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Thrust piece -MP3-411 (VW 454)- t  Pipe section -MP3-414 (VW 516)- t  Multi-purpose tool -MP3-419 (VW 771)- t  Pressure spindle -MP3-423 (VW 407)- t  Drive bushing -MP3-427 (40 - 21)- t  Pressure spindle -MP3-448 (VW 408A)- t  Pipe section -MP3-450 (VW 415 A)- t  Thrust piece -MP3-453 (VW 431)- t  Pressure washer -MP3-460 (VW 512)- t  Pipe section -MP3-461 (VW 519)- t  Thrust plate -MP3-467 (40-105)- t  Washer -MP6-415 (3260)- t  Bushing -T30010 (VW 540/1B)- t  Retaining plate -T30027 (VW 801)- t  Thrust piece -T30042 (2050)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/7- t  Separating device 22...115 mm, e.g. -Kukko 17/2- t  Extractor, e.g. -Kukko 18/2- t  Interior extractor 46...58 mm, e.g. -Kukko 21/7- t  Interior extractor 56...70 mm, e.g. -Kukko 21/8- t  Countersupport e.g. -Kukko 22/2- t  Feeler gauge

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

t	If the output shaft or tapered-roller bearing is replaced, it is necessary to adjust the output shaft → Chapter.

t	Both tapered-roller bearings are replaced together.

1 -	Clutch housing

2 -	Oil deflecting washer

3 -	Curved washer

q	removing → Fig.

q	installing → Fig.

q	replace after disassembly → Electronic Catalogue of Original Parts

4 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

5 -	Inner ring/tapered-roller bearing

q	pressing off → Fig.

q	pressing on → Fig.

6 -	Output shaft

q	1st to 4th gear

q	adjust → Chapter

7 -	Needle bearing

q	for 2nd gear

8 -	2nd gear sliding gear

9 -	Synchronizer ring

q	(Inner ring for 2nd gear)

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

10 -	Outer ring for 2nd gear

q	position on the synchronizer ring -Pos. 9-

q	replace if there are any traces of scoring or friction

q	Fitting position → Fig.

11 -	2nd gear synchronizer ring

q	check for wear → Fig.

q	Fitting position → Fig.

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

q	after removing the circlip -Pos. 13- press off with the 2nd gear sliding gear → Fig.

q	disassembling → Fig.

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

q	Fitting position → Fig.

q	pressing on → Fig.

13 -

Circlip

14 -	1st gear synchronizer ring

q	check for wear → Fig.

q	insert in such a way that the recesses lock into the arresters of the sliding sleeve/synchronizer body Pos. 12

15 -	Outer ring for 1st gear

q	insert into synchronizer ring Pos. 14, fitting position → Fig.

q	replace if there are any traces of scoring or friction

16 -	Synchronizer ring

q	(Inner ring for 1st gear)

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

17 -	Needle bearing

q	for 1st gear

18 -	1st gear sliding gear

q	Fitting position → Fig.

19 -	Thrust washers

q	for 1st and 4th gear

q

2 pieces

q	Insert peg of thrust washer into the hole of the output shaft

20 -

Washer

q	holds the thrust washers pos. 19 in the correct position on the output shaft

21 -	Needle bearing

q	for 4th gear

22 -	4th gear sliding gear

23 -	4th gear synchronizer ring

q	check for wear → Fig.

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

q	after removing the circlip -Pos. 25- remove with the 4th gear 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.

25 -

Circlip

26 -	3rd gear synchronizer ring

q	check for wear → Fig.

27 -	Outer ring for 3rd gear

q	fit into synchronizer ring -Pos. 26-, fitting position → Fig.

q	replace if there are any traces of scoring or friction

28 -	Synchronizer ring

q	(Inner ring for 3rd gear)

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

29 -	Needle bearing

q	for 3rd gear

30 -	3rd gear sliding gear

q	Fitting position → Fig.

31 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

32 -

Circlip

q	determine the thickness again when replacing the tapered-roller bearing Pos. 31 and the output shaft Pos. 6 → Fig.

33 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

34 -	Adjusting washer

q	Determine thickness → Chapter

35 -	Gearbox housing

Removing curved washer -A- from the output shaft

Press curved washer into the output shaft up to the stop –  Press curved washer up to the dimension -a- into the output shaft.    Dimension -a- = 2 mm + 0.5 mm.   Note Press in curved washer max. 3 mm - not deeper.

Remove outer ring/tapered-roller bearing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 56...70 mm, e.g. -Kukko 21/8-

Press outer ring/tapered-roller bearing into the clutch housing –  Support the clutch housing with a pipe section -MP3-450 (VW 415 A)- directly below the bearing support.

Removing inner ring/tapered-roller bearing –  First remove the circlip. –  Before fitting the extractor, position thrust piece -MP3-453- in output shaft and lay thrust plate -MP3-467- over it.

Pressing off 3rd and 4th gear synchronizer body/sliding with sliding gear for 4th gear –  First remove the circlip ( → Item). A -  Extractor, e.g. -Kukko 18/2- B -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Sliding sleeve and synchronizer body for the 1st and 2nd gear After removing the circlip ( → Item) jointly press off the 2nd gear sliding gear and the sliding sleeve/synchronizer body.

Pressing off inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Press on inner ring/tapered-roller bearing

Check 1st, 2nd and 3rd gear inner ring for wear –  Press the inner ring -2- on the cone of the sliding gear and measure clearance -a- with a feeler gauge -1-.

Clearance -a-	Fitting dimension	Wear limit
1st, 2nd and 3rd gear	0.75…1.25 mm	0.3 mm

Check 1st, 2nd and 3rd gear synchronizer 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 -1-.

Clearance -a-	Fitting dimension	Wear limit
1st, 2nd and 3rd gear	1.2…1.8 mm	0.5 mm

Fitting position of the outer ring, inner ring and 2nd gear synchronizer ring –  Position the inner ring -A- on the 2nd 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-.

Disassembling and assembling the sliding sleeve and 1st, 2nd as well as 3rd and 4th gear synchronizer body 1 -  Spring 2 -  Arresters 3 -  Sliding sleeve 4 -  Synchronizer body –  Slide the sliding sleeve over the synchronizer body into fitting position → Fig. or → Fig.. The recesses for the arresters on the synchronizer body and the sliding sleeve must be positioned above one another.

Disassembling and assembling the assembly of the sliding sleeve and 1st, 2nd as well as 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 end of the spring must grip into the hollow arrester.

Fitting position of the 1st and 2nd gear sliding sleeve/synchronizer body The groove marking -arrow 1- and the narrow collar -arrow 2- of the synchronizer body point to the 1st gear.

Press on the sliding sleeve/1st and 2nd gear synchronizer body –  Install circlip.

Fitting position of the 1st or 3rd gear outer ring The pegs -arrows- point towards the synchronizer body/sliding gear -A-.

Fitting position for synchronizer ring -A- (inner ring for 1st or 3rd gear) The pegs -arrows 1- lock into the recesses -arrows 2- of the synchronizer ring -B-.

Fitting position 1st and 3rd gear sliding gear The higher collar -A- points towards the 2nd or 4th gear -B-. The recesses in the collar -arrows- lock into the pegs of the outer ring (arrows → Fig.).

Fitting position of the sliding sleeve/3rd and 4th gear synchronizer body The wider collar of the synchronizer body -arrow- points towards the 3rd gear.

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

Checking 4th gear synchronizer 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
4th gear	1.0…1.7 mm	0.5 mm

Press on inner ring/tapered-roller bearing –  Determine the circlip → Fig. and install.

Determining the circlip –  Determine the thickest circlip - that can be fitted - and insert. The following circlips are available:

Thickness (mm)
1,79	1,89	1,98
1,83	1,92
1,86	1,95

Part number → Electronic Catalogue of Original Parts.

Remove outer ring/tapered-roller bearing from gearbox housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing –  First position adjusting washer under outer ring. –  Support the gearbox housing with a thrust piece -T30042 (2050)- directly below the bearing support.