Skoda Workshop Service and Repair Manuals

Disassembling and assembling differential gear Special tools and workshop equipment required t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/3- t  Pressure spindle -MP3-408 (VW 412)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-448 (VW 408 A)- t  Thrust piece -MP3-459 (VW 473)- t  Thrust plate -MP3-464 (30-205)- t  Bushing -MP3-474 (3144)- t  Thrust plate -MP3-467 (40-105)- t  Thrust plate -MP3-468 (2007)- t  Interior extractor 46 through 58 mm -Kukko 21/7- t  Countersupport -Kukko 22/2-

Press outer ring/tapered-roller bearing out of clutch housing –  First remove support bushing for sealing ring/flange shaft.

Press outer ring/tapered-roller bearing into the clutch housing No adjusting washer is fitted at the side of the clutch housing.

Remove inner rings/tapered-roller bearing –  Before fitting the extractor, position pressure plate -MP3-467 (40-105)- on the differential housing.   Note Both inner rings/tapered-roller bearings of the differential gear housing are removed in the same way.

Press on inner rings/tapered-roller bearing   Note The inner ring/tapered-roller bearing for the gearbox housing and clutch housing are pressed on with the same special tools.

Remove outer ring/tapered-roller bearing from gearbox housing A - e.g. Countersupport -Kukko22/2- B - e.g. Interior extractor 46..58 mm -Kukko21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing –  Position adjusting washer under outside ring. –  Support the gearbox housing with a bushing -MP3-474 (3144)- directly below the bearing support. For vehicles Octavia II

Difference between the tensioning sleeves

Dimension „a“ mm		Distinguishing feature
28.5 (short tensioning sleeve)		with round slot -arrows-
removing and installing → Fig.
36.0 (long tensioning sleeve)		without round slot
removing → Fig.
installing → Fig.

Assign differential gear housing The hole in the differential gear housing was adapted due to the longer tensioning sleeve. –  Check the hole for the tensioning sleeve in the differential gear housing.

Bore		Length of tensioning sleeve (mm)
»A«		28.5 (short tensioning sleeve)
»A« and »B«		36.0 (long tensioning sleeve)

Remove and install the short tensioning sleeve (with round slot) for the differential bevel gear shaft Removing –  Cover inner ring/tapered-roller bearing and drive wheel for speedometer to avoid any possible damage and swarf. –  Drive out tensioning sleeve with a chisel, position the chisel in the circular slot. Install –  Drive into the differential gear housing up to the stop. Continued for all vehicles

Remove the long tensioning sleeve (without round slot) and press off the differential bevel gear shaft The tensioning sleeve is sheared off when pressing out. –  Drive the remaining part of the tensioning sleeve out of the differential gear housing

Install long tensioning sleeve (without round slot) –  Adjust the hole in the differential bevel gear shaft at the hole in the differential gear housing. –  Drive in the new tensioning sleeve to the dimension -a- = 3.0 mm. The tensioning sleeve must not come in contact with the gearbox when the differential gear housing is installed.

On certain gearboxes the stop disc compound was provided with lands -A- in the area of the openings. Therefore the differential gear housing was provided with a round slot -B-. –  Install stop disc compound with gearbox oil. –  Insert the stop disc compound in such a way that it locks into the slot -B- in the differential gear housing.

Install differential bevel gears –  Install stop disc compound with gearbox oil. –  Insert both large differential bevel gears and secure (e.g. with flange shaft). –  Insert both small differential bevel gears with a 180° offset. –  Push in the differential bevel gear shaft -arrow A- up to the first small differential bevel gear. –  Insert the threaded parts -arrows B- in the large differential bevel gears. Fitting position: Shoulder towards differential bevel gear

Fitting position of thrust washer for the conical ring -1- The collar -arrow- points towards the pressure spring -B-. The lands -A- are available on certain gearboxes. The lands -A- point towards the conical ring -1-. –  Drive in the differential bevel gear shaft up to end position and secure with tensioning sleeve.