Skoda Workshop Service and Repair Manuals

Disassembling gearbox

–  Secure gearbox to the assembly stand -arrows-. –  Position catch pan underneath. –  Drain out gear oil.

–  Release screws -arrows-. –  Separate the clutch release lever together with the release bearing and guide bushing from the drive shaft and ball stud. –  Release fixing screw for right flange shaft. To this end insert two screws in the flange and counterhold the flange shaft using a tyre iron. –  Pull out the flange shaft with pressure spring, stop disc and conical ring.

–  Unscrew the cover -arrow- for the gearbox housing carefully remove.

–  Pull out the bearing bolt -1- for the 5th/6th gear shift fork -2- in -direction of arrow- and remove gearshift fork.

–  Unscrew screws -A- for inner rings of the bearing on the input and output shaft, to this end engage the 5th gear -arrow 1- and the 1st gear -arrow 2- and -arrow 3-. –  The input and output shafts are blocked after enagaging 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 screw-tap in order to remove locking agent residues.

–  Remove 6th gear pinion with inner ring/cylindrical-roller bearing for output shaft. A -  Two-arm extractor -Kukko 20/10- B -  Allen screw -M8 x 15-

–  Tighten the separating device - Kukko 17/1--A- behind the running gear (not behind the engaging gearing) of the 6th gear sliding gear -arrow-. A -  Separating device -Kukko 17/1- B -  Allen screw -M8 x 15- C -  Extractor -Kukko 18/1- –  Remove 6th°gear pinion with inner ring/cylindrical-roller bearing for input shaft and thrust washer. –  Remove the sliding sleeve for 5th/6th °gear with the arresters.

–  Insert the separating device - Kukko 17/1--A- below the synchronizer ring of the 5th gear -1-. The synchronizer ring is thereby pressed onto the synchronizer body -2-. A -  Separating device -Kukko 17/1- B -  Allen screw - M8 x 15- C -  Extractor -Kukko 18/1- –  Pull off 5th/6th °gear synchronizer body with inner ring for 6th °gear needle bearing and 5th °gear synchronizer ring.   Note The 5th °gear synchronizer ring must always be replaced after removing → Electronic catalogue of original parts. –  Unscrew the fixing screw for the left flange shaft -1-, to this end insert two screws in the flange and counterhold the flange shaft using a tyre iron.

–  Remove the flange shaft -1- with pressure spring. –  Remove the bushing -2- and the 5th °gear sliding gear with needle bearing -4-. –  Unscrew hexagon collar nut -5- for shift mechanism (fitting of the reverse gear). –  Release the fixing screws -6- for the bearing support of the drive shaft and output shaft. –  The 5th °gear pinion -3- is later pressed off when removing the bearing support for the grooved ball bearings → Chapter. –  Turn the gearbox in the assembly support with the clutch housing upwards. –  Release fixing screws, that serve to secure the gearbox housing from the clutch housing. –  Carefully release the clutch housing from the projecting housing lands and make sure the sealing surfaces are not damaged in the process. –  When removing, the clutch housing must not tilt so that the roller bearing and the bearing assembly on the drive shaft and the output shaft are not damaged.

–  Remove the differential gear -A- from the gearbox housing.

–  Afterwards, remove the oil drip pan -A- and the oil guide part -B- with the solenoid from the gearbox housing. Vehicles with start-stop system

–  Remove transmission neutral sender -G701--arrow-. Continued for all vehicles

–  Remove the gearshift shaft with cover -A-. To do so put the gearshift shaft into Neutral. Subsequently unscrew screws -arrows- and remove the gearshift shaft from the gearbox housing. –  Remove the bearing pins -B- at the top of the gearbox. –  Unscrew the reversing lights switch -F4--C-.

–  Unscrew screw -A- for securing the reverse wheel shaft. –  Remove the bearing pins -B- at the gearbox bottom side.   Note Do not remove the cover -arrow- to disassemble the gearbox.

–  Press off the drive shaft and output shaft together with the 5th °gear sliding gear -A-, bearing support, gearshift mechanism (shift forks) and reverse gear.   Note t  Position the gearbox housing in such a way that the dowel sleeves in the gearbox housing are not damaged. t  During the pressing off procedure request the assistance of second mechanic to prevent components from falling. –  Pressing off the drive and output shafts from the bearing support with grooved ball bearings and 5th gear pinion → Chapter.