Skoda Workshop Service and Repair Manuals

Removing gearbox housing cover and 5th gear

–  Secure gearbox to gearbox mount -T30109 (VW 353)- with screws -arrows-. –  Remove clutch release lever with release bearing → Chapter. l  If the 5th gear is installed again, then the input shaft and output shaft bearings must not be damaged.

l  Therefore, while securing the gearbox to the gearbox mount -T30109 (VW 353)- the following tools 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  Thrust piece -T10030/4- l  The drive shaft must only be supported with the insertion tool -MP3-466 (32-111)- at a later stage. 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)-

–  Unscrew the gearbox housing cover -arrow-.

–  Check whether the extraction hooks -T10040/2A- can be correctly positioned under the 5th gear pinion.

The extraction hooks -T10040/2A- cannot be correctly positioned.
-A- the extraction hooks -T10040/2A- come prematurely in contact with: t  the gearbox housing wall t  the ribbing of the gearbox housing below the 5th gear pinion	Remove „together“: „5th gear synchronizer body“, „5th gear pinion“ and „gearbox housing“ → Chapter
-B- the extraction hooks -T10040/2A- come in contact with the ribbing in the gearbox housing below the 5th gear pinion.

The extraction hooks -T10040/2A- can be correctly positioned.

5th gear can be removed separately → Anchor.

Remove 5th gear separately

Remove 5th gear shift fork as follows: –  Cover the openings with a cloth. –  Put shift fork -1- in Neutral position. –  Remove screw -2- with 5th gear shift gate -3-. –  Remove screws -4- for the bearing pins. –  Remove bearing pins -direction of arrow-. –  Remove 5th gear shift fork.   Note The 5th gear sliding sleeve must not be removed.

–  Unscrew screws -A- for synchronizer body and 5th gear pinion. To this end engage the 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. The input and output shafts are blocked after introducing the two gears, the synchronizer body and pinion cannot rotate. 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 screw-tap in order to remove locking agent residues. Pull off 5th gear synchronizer body together with sliding sleeve and arresters. Use extractor - T10309-. –  First of all insert a shell -T10309/1- between the 5th gear pinion -A- and the support of the 5th gear shift fork -B-.

l  The shell -T10309/1- must be positioned below the synchronizer ring. –  If necessary, the shell must be pressed into the end position. –  Turn the shell -T10309/1- to the opposite side -direction of arrow-.

–  Insert the threaded insert -T10309/3- into the shell. –  Now insert the second shell -T10309/1- and position the pipe -T10309/2- onto the assembly device. –  Check the synchronizer body for damage after removing. –  Replace 5th gear synchronizer ring. –  Remove the 5th gear sliding gear with needle bearing.

–  Remove the 5th gear pinion as follows: –  First of all insert the extraction hook-A-. B -  Screw M10 x 20, SW 17 –  If necessary, heat the gear pinion using the hot-air blower -V.A.G 1416-.   Note t  The 5th gear pinion can also be removed using the two-arm extractor -Kukko 20/10- in combination with the extraction hooks -T10040/2A-. t  When pulling off the gear pinion make sure the hooks do not bend outwards. Check 5th gear for damage after removing.