Skoda Workshop Service and Repair Manuals

Install –  Insert differential gear.

–  Always replace O-rings -arrows- for bearing support/output shaft → Electronic Catalogue of Original Parts.   Note The fig. only shows 3 of the 4 gasket rings.

Gearbox with reverse gear pinion ► 08.10 -arrow-

–  Insert together the drive shaft -1- and the drive shaft -2-. –  Tighten nuts for the bearing support/output shaft to tightening torque → Chapter. –  Position the reverse gear pinion -3- onto the needle bearing in the clutch housing. The shoulder -arrow- points away from the clutch housing. –  Check if the reverse shaft -4- is complete → Chapter; do not yet position the reverse shaft support onto the reverse shaft. –  Insert the reverse shaft in the clutch housing. –  Clean all threaded holes in the reverse shaft support to remove locking agent; clean with a screw-tap. –  Position reverse shaft support on the reverse shaft.

–  Mount the reverse gear shift fork -1- with the support for reverse gear shift fork -2-, the spring -3- and the sliding block -4-.

Fitting location of reverse gear:

–  Screw on shift mechanism/reverse gear -A- and tighten to the specified tightening torque → Chapter. –  Install shift forks -B- together with shift rails. The stud -C- of the reverse gear support is located in front of the shift rails.

Gearbox with reverse gear sliding sleeve 08.10 ► -arrow- l  Clean all threaded holes in the reverse shaft support to remove locking agent; clean with a screw-tap. l  Position the input shaft, the output shaft and the reverse shaft to each other. l  The engaging gearing -arrow- of the reverse gear sliding sleeve points to the reverse gear sliding gear.

–  Insert together the input shaft -1-, the output shaft -2- and the reverse shaft -3-. The output shaft -2- comes in contact with the differential gear. –  If necessary, turn the differential gear (2 mechanics) so that the output shaft -2- can be inserted into the clutch housing. –  Tighten nuts for bearing support/output shaft to tightening torque → Item

–  Mount shift forks -A- together with shift rails. The reverse gear support -B- is located in front of the shift rails. –  The shift rail for the reverse gear grips into the reverse gear sliding sleeve -arrow-. Continued for all

–  Screw the studs -A- M8 x 100 mm in the reverse shaft support, to ensure it is aligned once the gearbox housing has been fitted. –  Align shift rails.   Note The shift segments must be positioned in the slots of the sliding sleeves. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the clutch housing. –  Fit gearbox housing.

Insert the screws for the reverse shaft support -arrow- as follows: –  Insert screw -a-, unscrew pin screw (⇒ Abb. S34-0314), replace screw -b- and -c-. Tightening sequence: 1 -  Screw -a- 30 Nm 2 -  Screw -b- 25 Nm ⇒ fig. S34-1036 3 -  Screw -c- 25 Nm

–  Tighten screw -b- for support reverse shaft.

–  Fit bearing pins -arrow- for shift forks. Align the shift mechanism with a screwdriver to ensure the relevant bearing pin can be fitted. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the cap. –  Fit gearshift shaft cap and tighten screws to tightening torque → Chapter.

Install the gearshift shaft with cover as follows: –  Put the shift rails in neutral position. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the cover. –  Put the gearshift shaft into Neutral. –  Align the gearshift shaft in such a way that the shift finger -arrow 2- is inserted in the shift rails. –  Screw on gearshift cover → Chapter.

–  Install both flange shafts with pressure springs, stop discs and conical rings. Install 5th/6th gear

l  If the 5th/6th gear is mounted again, the bearing of the input shaft and of the output shaft must not be damaged. l  Make sure that the supporting bridge -MP3-425 (30-211 A)- and the supporting device -T10323- are installed. –  Lock the screw of the supporting bridge -MP3-425 (30-211 A)- with the nut -A-.

Fitting position of the 5th gear pinion The round slot -arrow- points to the gearbox housing.

–  Drive in 5th gear pinion

Check 5th gear synchronizer ring and 6th gear synchronizer ring –  Press the synchronizer rings on the cone of the sliding gear and measure the clearance -a- with a feeler gauge before installing the wheel and the 5th gear snychronizer ring and the 6th gear snychronizer ring.

Clearance -a-	Fitting dimension	Wear limit
5th/ 6th gear	1.1 ... 1.7 mm	0.5 mm

–  Mount the 5th gear sliding gear with needle bearing. As of production date 26.05.08: Position the corrugated spring ring onto the 5th gear sliding gear. Octavia II → Item. Superb II → Item. –  Position the 5th gear synchronizer ring on the sliding gear. –  If disassembled, assemble the 5th/6th gear synchronizer body/sliding sleeve before installation → Chapter. Deeper recesses are present on both sides in the 5th/6th gear sliding sleeve on gearboxes as of production date 06.06 → Chapter.

Fitting position of the 5th/6th gear synchronizer body/sliding sleeve The shoulder -arrow 1- points towards the 6th gear. The supports -arrows 2- of the synchronizer body are on the same line as the integrated arresters of the synchronizer ring (arrows in the Fig. S34-1004 → Fig.).

5th gear synchronizer ring and 6th gear snychronizer ring with integrated arresters -arrows- –  Cover all openings with a cloth so that no foreign bodies can get into the gearbox.

–  Drive in synchronizer body for 5th and 6th gear.   Note Pay attention to the free travel of the synchronizer ring during the driving in operation.

–  Heat the inner ring for the cylindrical-roller bearing of the 6th gear to max. 100°C and drive onto the drive shaft.   WARNING Wear protective gloves! –  Mount 6th gear synchronizer ring As of production date 26.05.08: Position the corrugated spring ring onto the 6th gear synchronizer ring Octavia II → Item. Superb II → Item. –  Mount the 6th gear sliding gear with needle bearing.

–  Heat the inner ring for the cylindrical-roller bearing -B- to max. 100°C and drive onto the drive shaft. Guide inner ring for the cylindrical-roller bearing -B- together with axial washer -A-   WARNING Wear protective gloves!   Note The shape of the inner ring -B- for cylindrical roller bearing was modified → Chapter as of 09.06. Fitting position of the 6th gear pinion

–  Mount sleeve -A- onto the 5th gear pinion.

The groove -B- points away from the sleeve -A-. »Or« the groove -arrow 1- in the collar -arrow 2- points away from the sleeve -A- (see previous fig. S34-1043). –  Heat the 6th gear pinion to max. 100 °C.   WARNING Wear protective gloves!   Note t  Shift the sliding sleeve for 5th/6th gear into idle position so that through this the 6th gear sliding gear can turn when pressing on the 6th gear pinion. t  When pressing on the 6th gear pinion, ensure that the serration of the pinion for the 6th gear and the 6th gear sliding gear are in mesh. –  Drive in 6th gear pinion

–  Heat the inner ring for the cylindrical-roller bearing -A- to max. 100°C and drive onto the output shaft.   WARNING Wear protective gloves!

–  Remove supporting bridge -MP3-425 (30-211 A)- and supporting bridge -T10323-.

If it is not yet performed, clean the threaded holes of the fixing screws -A- for the 5th/6th gear synchronizer body and the 6th gear pinion e.g. using a screw-tap in order to remove locking agent residues. Otherwise there is a risk that the screws will shear. –  2 gears must be engaged -arrows 1 to 3- before tightening the fixing screws -A-. –  Screw in new fixing screws -A- for the synchronizer body and the 5th/6th gear sliding gear and tighten to tightening torque. Octavia II → Chapter. Superb II → Chapter. –  Install 5th/6th gear shift fork.

Setting 5th/6th gear (up to production date 05.06 - Octavia II) –  Engage 5th gear. –  Release screw -1-. –  Insert both feeler gauges -A- 0.5 mm via the two shift segments (to 6th gear) into the sliding sleeve. –  Press the sliding sleeve and the shift fork in the -direction of the arrow- and tighten screw -1- to tightening torque → Chapter. 5th gear engaged.

l  Control measurement: a feeler gauge of 0.5 mm can be inserted clearance free between sliding sleeve and both shift segments -arrow- on the side towards the 6th gear. –  If necessary, repeat the adjustment procedure. –  Engage the 5th gear and then the 6th gear. If the 5th or 6th gear is engaged, the 5th/6th gear shift fork must have a minimum play in the shift fork. –  Remove gear. l  The sliding sleeve must now be in Neutral. The synchronizer ring must travel freely. –  Shift through all gears consecutively.

Setting 5th/6th gear (as of production date 06.06) –  Engage 5th gear. –  Release screw -1-. –  Press the sliding sleeve and the shift fork in the -direction of the arrow- and tighten screw -1- to tightening torque → Chapter. 5th gear engaged.

l  Control measurement: a feeler gauge of 0.2 mm -arrow- must not be inserted between sliding sleeve and both shift segments on the side towards the 6th gear. –  If necessary, repeat the adjustment procedure. –  Engage the 5th gear and then the 6th gear. If the 5th or 6th gear is engaged, the 5th/6th gear shift fork must have a minimum play in the shift fork. –  Remove gear. l  The sliding sleeve must now be in Neutral. The synchronizer ring must travel freely. –  Shift through all gears consecutively. –  Apply sealant -AMV 188 200 03- uniformly on the sealing surface of the cover for the gearbox housing. –  Install the gearbox housing cover -arrow- and tighten the screws to tightening torque. Octavia II → Chapter.

Superb II → Chapter. For vehicles with four-wheel drive (Octavia II)

–  Install left flange shaft with pressure spring, stop disc and conical ring. –  Attach angle gearbox to gearbox and tighten connecting screws crosswise to tightening torque → Chapter, always replace screws → Electronic Catalogue of Original Parts.   Note When attaching the angle gearbox to the gearbox slowly turn the flange shaft (slowly push angle gearbox to gearbox up to stop).

–  Tighten the screw of the flange shaft -arrow 1- with socket insert -T10107A- to tightening torque → Chapter. Continued for all vehicles

–  Install both flange shafts with pressure springs, stop discs and conical rings. –  Installing the release lever, clutch release bearing and guide bushing → Chapter. –  Fill gearbox with oil → Chapter. Gearbox oil specification and capacity Octavia II → Chapter. Superb II → Chapter.