Skoda Workshop Service and Repair Manuals

Disassembling gearbox

–  Secure the gearbox to the gearbox mount -T30109 (VW 353)- with the screws -arrows-. –  Place catch pan underneath. –  Drain out gear oil → Chapter. –  Removing the clutch release lever, clutch release bearing and guide bushing → Chapter. l  The bearing of the input shaft and of the output shaft must not be damaged when removing and installing the 5th/6th gear.

l  Therefore, while securing the gearbox to the gearbox mount -T30109 (VW 353)- the following devices must be installed for support: Below the drive shaft: t  Supporting bridge -MP3-425 (30-211 A)- t  Insertion tool -MP3-466 (32-111)- t  Assembly device -T10030/4- l  Lock the screw of the supporting bridge -MP3-425 (30-211 A)- with the nut -A-. Below the bearing support for the output shaft: t  Supporting bridge -T10323- t  Pressure plate -MP6-414/7 (3253/7)- from assembly device -MP6-414 (3253)- t  Pressure washer -MP3-456 (VW 447 i)- For vehicles with four-wheel drive (Octavia II)

–  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-.   Note

A heat shield -arrow A- is located on the top side of the angle gearbox. One of the two top connecting screws is located under this shield -arrow B-. –  Unscrew top engine/gearbox connecting screws -arrow C- and -arrow B-. When slackening the screw -arrow B- slightly raise the heat shield -arrow A-. –  Carefully remove angle gearbox. Continued for all vehicles

–  Unscrew the gearbox housing cover -arrow-. –  Carefully release the cover alternatively from the projecting ribbing and make sure the sealing surfaces are not damaged in the process.

–  Remove shift fork and 5th/6th gear sliding sleeve as follows: –  Engage 5th gear (arrows -1- and -2-). –  Remove 5th/6th gear shift gate (screw -A-). –  Then unscrew both screws -B- for bearing bolt. –  Pull out bearing bolt. –  Remove 5th/6th gear shift fork.

–  Unscrew screws -A- for inner rings/bearings on the input and output shaft, to this end engage the 5th gear -arrow 1- and the 1st gear -arrows 2 and 3-. –  The input and output shaft is blocked after engaging both gears. Now it is possible to release the two bolts.   Note If the shafts are not replaced, carefully clean the threaded holes e.g. using a thread tap to remove locking agent residues. For vehicles with four-wheel drive (Octavia II)

–  Remove the left flange shaft. –  Take out the flange shaft with pressure spring, stop disc and conical ring. Continued for all vehicles

–  Remove both flange shafts. –  Remove both flange shafts with pressure springs, stop discs and conical rings.

–  Remove two screws -arrows- for support/reverse shaft.

–  Now remove the 3rd screw -arrow- for reverse shaft support.

–  Remove gearshift shaft with cover Put the gearshift shaft into Neutral. Subsequently unscrew screws -arrows- and remove the gearshift shaft from the gearbox housing.

–  Remove cap -A- and bearing pins -B- at the bottom of the gearbox.

–  Release screws -A-, that serve to secure the gearbox housing from the clutch housing.   Note Do not release nuts -B- for the output shaft bearing support.

–  Remove bearing pins -A- on the top side of the gearbox and fixing screws -B- for the gearbox housing on the clutch housing near the differential gear.

Remove the following components together with the gearbox housing: t  Synchronizer body for 5th/6th gear t  6th gear pinion t  5th gear pinion l  Both clips -T10408/3- must be attached to the 5th gear pinion so that the clips are always located opposite each other above the recess of the housing -arrows-.

Use the extractor plate -T10408 - with the pressure pieces -T10408/2-, the clips -T10408/3- and the extractors Kukko 18/1. –  Tighten the extractor plate -T10408- in the threaded bores for the cover of the gearbox housing. A -  Screws M7 x 35 with washers Tightening torque - 18 Nm –  Position the pressure pieces -T10408/2- onto the shafts. –  2 Install extractors, e.g. -Kukko 18/1-.   Note If necessary, heat the 5th gear pinion and the 6th gear pinion using the hot-air blower e.g. -V.A.G 1416-.

–  Remove 5th/6th gear synchronizer body, 6th gear pinion, 5th gear pinion and gearbox housing by alternatively tightening the spindles -A- (1/2 turn) of the extractors e.g. -Kukko 18/1-.

–  Remove shift forks -A- together with shift rails. –  Unscrew shift mechanism/reverse gear -B- (previous fig.)

–  Release nuts -B- for the bearing support/output shaft.

Gearbox with reverse gear pinion ► 08.10

–  Successively remove the reverse gear -A-, drive shaft -B- and output shaft -C- from the clutch housing.

Gearbox with reverse gear sliding sleeve 08.10 ► -arrow-

–  Remove the input shaft -1-, the output shaft -2- and the reverse shaft -3- together from the clutch housing. Continued for all –  Remove differential gear.