Skoda Workshop Service and Repair Manuals

Disassembling gearbox (Octavia II) Four-wheel drive

–  Remove the right flange shaft bolt -arrow- using the socket insert -T10107A-.   Note The right flange shaft remains in the angle gearbox.

–  Unscrew the bottom engine/gearbox connecting screws -arrows-.

On certain vehicles a heat shield -arrow A- is located on the top side of the angle gearbox. The screw -arrow B- is accessible below the heat shield. The screw -arrow C- is accessible above the heat shield. –  Carefully press off angle gearbox from manual gearbox, while doing so secure it against falling. Continued for all gearboxes   Note Before disassembling the gearbox first the gearbox mount -T30109 (VW 353)- should be secured to the gearbox → Anchor.

Secure the gearbox mount -T30109 (VW 353)- to the gearbox.

–  Attach gearbox to assembly stand -MP9-101-. –  Place catch pan underneath. –  Drain out gear oil.

–  Remove slave cylinder with release bearing -arrows-.

Make sure that the gearshift shaft is not blocked by the locking angle -arrow-. –  Put the gearshift shaft into Neutral. –  Remove switch for reversing lights -F4--1-. –  Unscrew locking screw -2-. –  Unscrew bolts -3-. –  Pull the gearshift shaft -4- out of the gearbox housing.

–  Release the fixing screw for the left flange shaft, to this end insert two screws in the flange and counterhold the flange shaft using an assembly lever. –  Remove the flange shaft with pressure spring. Front-wheel-drive –  Remove rigid shaft or right flange shaft.   Note For gearboxes as of production date 11.04, the rigid shaft (right) was replaced by a flange shaft. Continued for all gearboxes

–  Unscrew screws -B-, that serve to secure the gearbox housing from the clutch housing.   Note The hexagon bolt -arrow- is located outside the screw-on flange. It is fitted with a washer.

–  Interlock the drive shaft by fitting the press-on sleeve -VW 455 (MP3-412)- via the drive shaft onto the clutch housing.   Note

If necessary the bushing -3160 (T30102)- must be used instead of the insertion bushing -VW 455 (MP3-412)- so that the separating device-A- can be tensioned behind the splines of the drive shaft. –  Tighten the separating device-A-, e. g. -Kukko 17/0- behind the splines of the drive shaft. While doing so the reverse side of the separating device must rest on the insertion bushing -VW 455 (MP3-412)- or on the bushing -3160 (T30102)- with no play.

–  Push the rubber through the middle of the cap -1- using a screwdriver. –  Carefully lever up the cap from the gearbox housing using the screwdriver -2-.

Remove the circlip -C- from the grooved ball bearing of the drive shaft/gearbox housing as follows: –  with the screw driver-A- hold one end of the circlip. –  With the screw driver-B- lever the other end out of the slot of the grooved ball bearing -direction of arrow-. –  Move screwdriver-B- around, levering out the circlip step by step.

–  If applicable, remove the washer -1- from the gearbox housing -2-. l  If the gearbox housing is replaced, check whether the washer -1- must be fitted again → Anchor.

–  Remove the fixing screws -A- for the gearbox housing on the clutch housing.

–  Screw adapter -MP3-419/40- into the threaded hole of the gearbox housing. –  Heat the gearbox housing with the hot-air blower at the bearing assembly for grooved ball bearing/drive shaft to about 100°C for around 10 minutes. –  Remove the gearbox housing from the clutch housing using the multi-purpose tool -MP3-419/1--direction of arrow-.   Note If necessary carefully release with assembly lever alternatively from the projecting housing lands and make sure the sealing surfaces are not damaged in the process.

–  Remove the separating device-A- and the insertion bushing -VW 455 (MP3-412)- or the separating sleeve -3160 (T30102)- from the drive shaft.

–  If applicable, remove the washer -1- from the grooved ball bearing -2-. –  If the gearbox housing is replaced, check whether the washer -1- must be fitted again → Fig.. For the removal of the shafts from the clutch housing a second mechanic is required.

–  Lift the differential gear -1- with the left hand. With the right hand lift output shaft gears 1 through 4 together with gear shift rods -2--arrow A-. –  At the same time the 2nd mechanic lifts the drive shaft, the reverse shaft and the output shaft 5th/6th gear -3- together with the gear shift rods out of the clutch housing -arrow B-.   Note If necessary the differential gear can be placed again in the clutch housing after lifting the shafts. –  Removing gasket ring for drive shaft.   Note The grooved ball bearing on the drive shaft must always be replaced → Chapter.