Skoda Workshop Service and Repair Manuals

Assembling gearbox (Octavia II) l  A new grooved ball bearing must be pressed onto the drive shaft → Chapter.

–  Insert the drive shaft -1-, the output shaft 5th/6th gear -2- together with gear shift rod -3-, shift fork -4- and reverse shaft -5-.

–  Insert differential gear -1-. –  Take the output shaft gears 1 through 4 -3- with the gear shift rods -4- in the right hand as shown. –  Slightly lift the differential gear with the left hand. –  At the same time the 2nd mechanic lifts the drive shaft, the output shaft 5th/6th gear and reverse gear -2- together with the reverse shaft. –  Insert the output shaft gears 1 through 4 in -the direction of the arrow-. The serrations of the drive shaft, output shafts and final drive/differential gear must be in mesh. –  Place the shafts and the differential gear in their bearing assembly.

–  Secure the supporting bridge -MP3-425- for drive shaft to the clutch housing.   Note To provide a clearer illustration, the clutch housing is shown at an angle of 180°. –  Screw in screw -A- until the drive shaft is lifted slightly.

On certain gearboxes, flattened parts -A- are present at the grooved ball bearing for the drive shaft and at the bearing support -B-. Check the grooved ball bearing for the drive shaft and the gearbox housing.

Grooved ball bearing for the drive shaft and the gearbox housing

No flattened parts at the grooved ball bearing -A- and at the bearing support -B- → Anchor

Flattened parts at the grooved ball bearing -A- and at the bearing support -B- → Fig.

As of production date 20.03. 06 approx. up to production date 20.01. 08: A washer is inserted above and below the grooved ball bearing for the drive shaft → Chapter.

Top washer	Outer diameter	78.6 mm
Bottom washer	Outer diameter	85 mm

Measure the shoulder above the support for the grooved ball bearing

Shoulder above the grooved ball bearing	Dimension „a“	Top washer
up to production date 19.03. 06	10 mm	no
as of production date 20.03. 06	10.7 mm	yes

In the gearbox housing the area below the bearing pedestal for the grooved ball bearing is also changed -arrow-

Area below the bearing pedestal		Bottom washer
up to production date 19.03. 06	not chamfered	no
as of production date 20.03. 06	chamfered slightly deeper	yes

–  If necessary place a washer (outside diameter = 85 mm) -1- onto the grooved ball bearing -2-.

For certain gearboxes: If flattened parts -A- are present at the grooved ball bearing/drive shaft and at the bearing support -B- for the grooved ball bearing in the gearbox housing. l  Washers must not be placed above and below the grooved ball bearing on these gearboxes. l  The flattened parts -A- at the grooved ball bearing and at the bearing support -B- must be aligned in the gearbox housing. –  Mark these flattened parts in different colours. –  Transfer the markings onto the upper area of the grooved ball bearing and onto the upper area of the bearing support of the gearbox housing (⇒ next figure). –  On all gearboxes - heat the gearbox housing with the hot-air blower in the area of the bearing assembly for grooved ball bearing/drive shaft to 100°C for approx. 10 minutes.   Note t  Warming up is necessary so that the grooved ball bearing is not damaged when installing the gearbox housing. t  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the clutch housing.

t  Align the marking of the grooved ball bearing -A- to the marking on the gearbox housing -B- and position gearbox housing.

–  Tighten new screws -A-, -B- and -C- for the gearbox housing at the clutch housing to tightening torque. Assignment of screws: A -  Screw with captive washer B -  Screw without washer C -  Screw with captive washer

–  If necessary place a washer -1- (outside diameter = 78.6 mm) above the grooved ball bearing -2-.   Note t  If a washer must be placed onto the grooved ball bearing → Fig.. t  The washer -1- above the grooved ball bearing -2- is no longer fitted if there is a flattened part on the grooved ball bearing and the gearbox housing → Fig..

–  Install circlip -1- for grooved ball bearing/drive shaft. –  Remove supporting bridge -MP3-425- for drive shaft. –  In case the serrated sleeve for the gearshift shaft was removed, drive it in with the drift → Chapter up to the stop of the tool. –  Turn the gearbox with the opening for the gearshift shaft in the assembly stand upwards.

–  Insert the gearshift shaft -1- into the bottom bearing -2- and into the gearshift forks -3-. The cap in the illustration is removed for purposes of clear presentation.

–  Press the gearshift shaft -1- against the serrated sleeve -2--direction of arrow- and guide with the shift finger -3- through the gearshift forks up to the stop downwards. l  The gearshift cover -4- must be positioned at the same time parallel to the screw-on surface at the gearbox housing. l  The gearshift shaft must slide easily into the selector movement (upwards and downwards).   Note If the gearshift cover is positioned obliquely to the screw-on surface, the gearshift shaft is not inserted into the bottom bearing.

–  Tighten screws -3- for the cover/gearshift shaft -4-. –  Screw in locking screw -2-, at the same time the locking angle -arrow- must be laid out. –  Install switch for reversing lights -F4--1-.

–  Install left flange shaft with pressure spring, stop disc and conical ring. Front-wheel-drive –  Install rigid shaft or right flange shaft with pressure spring, stop disc and conical ring.   Note For gearboxes as of production date 11.04, the rigid shaft (right) was replaced by a flange shaft. Continued for all gearboxes

–  Drive in the gasket ring for the drive shaft. –  Install slave cylinder with release bearing → Chapter. –  Shift through all gears consecutively.

–  Drive the cap into the gearbox housing as far as the stop of the pressure plate -T10042-. –  Remove gearbox from assembly stand. Four-wheel drive Install angle gearbox as follows at the manual gearbox: –  On manual gearbox, lightly grease the rigid serration at differential gear with grease for the plug serration of the clutch disc - G 000 100-. –  Push angle gearbox fully onto the manual gearbox, while doing so slowly turn the flange shaft (carefully press angle gearbox onto gearbox up to stop).   Note t  Do not pull angle gearbox with the fixing screws against the manual gearbox, otherwise the angle gearbox can tilt and the fixing eyes can break off. t  Tighten gearbox/angle gearbox connecting screws crosswise (always replace screws → Electronic Catalogue of Original Parts). –  Attach angle gearbox to gearbox and tighten connecting screws crosswise to tightening torque → Chapter Pos. 17.

–  Tighten the screw of the flange shaft -arrow 1- with socket insert -T10107A- to tightening torque . → Chapter Pos. 16.