Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft Special tools and workshop equipment required t  Bushing -MP1-316 (30-100)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Pipe section -MP3-414 (VW 516)- t  Pressure spindle -MP3-423 (VW 407)- t  Thrust piece -MP3-431 (3002)- t  Pipe section -MP3-450 (VW 415 A)- t  Pipe section -MP3-451 (VW 422)- t  Distance sleeve -MP3-458/2- t  Flywheel type belt pulley fitting tool -MP9-400- t  Cap -T10080- t  Thrust piece -T10081- t  Insert base -T10083- t  Pressure plate -T10084A- t  Separating device, e.g. -Kukko 17/1- t  Extractor, e.g. -Kukko 18/1- t  Interior extractor, e.g. -Kukko 21/5- t  Countersupport, e.g. -Kukko 22/1- t  Hot-air blower -V.A.G 1416-   Note When installing new pinions observe the technical data: t  Fabia II → Chapter. t  Roomster → Chapter. t  Rapid → Chapter.   Note t  Insert all bearings, gears and synchronizer rings in the gearbox with gear oil. t  Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear. t  On gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are changed (the springs are longer), at the same time the synchronizer ring for 3rd and 4th gear is changed as of this date → Electronic Catalogue of Original Parts.

1 -

Circlip

q	always replace → Electronic Catalogue of Original Parts

q	Determine thickness → Chapter

2 -	Sliding sleeve with 5th gear synchronizer body

q	removing and installing → Chapter

q	disassembling → Fig.

q	Assembling sliding sleeve/5th gear synchronizer body → Fig. and → Fig.

q	on gearboxes as of production date 06.09, the springs -Pos. 27- are changed

3 -	5th gear synchronizer ring

q	check for wear → Fig.

4 -	5th gear sliding gear

5 -	Needle bearing

q

5th gear

q	replace together with -Pos. 6-

q	Assignment → Electronic Catalogue of Original Parts

6 -

Bushing

q	for 5th gear needle bearing

q	replace together with -Pos. 5-

q	press off with bearing support for grooved ball bearing → Fig.

q	pressing on → Fig.

q	Assignment → Electronic Catalogue of Original Parts

7 -	Gearbox housing

8 -	Bearing support for grooved ball bearing

q	Always replace grooved ball bearing together with the bearing support

q	If the bearing support is released from the gearbox housing, it must always be replaced

q	pressing off → Fig.

q	pressing on → Fig.

9 -	Drive shaft

10 -	Needle bearing

q	for 3rd gear

q	Assignment → Electronic Catalogue of Original Parts

11 -	3rd gear sliding gear

12 -	3rd gear synchronizer ring

q	on gearboxes as of production date 06.09, the synchronizer ring for 3rd and 4th gear is changed → Electronic Catalogue of Original Parts

q	check for wear → Fig.

13 -	Sliding sleeve with 3rd and 4th gear synchronizer body

q	press off with 3rd gear sliding gear → Fig.

q	disassembling → Fig.

q	Fitting position sliding sleeve/synchronizer body → Fig.

q	Assemble sliding sleeve/synchronizer body → Fig. and → Fig.

q	pressing on → Fig.

q	on gearboxes as of production date 06.09, the springs (-Pos. 23-) are changed

14 -	4th gear synchronizer ring

q	on gearboxes as of production date 06.09, the synchronizer ring for 3rd and 4th gear is changed → Electronic Catalogue of Original Parts

q	check for wear → Fig.

15 -	4th gear sliding gear

16 -

Bushing

q	for 4th gear needle bearing

q	replace together with -Pos. 17-

q	removing → Fig.

q	installing → Fig.

q	Assignment → Electronic Catalogue of Original Parts

17 -	Needle bearing

q	for 4th gear

q	replace together with -Pos. 16-

q	Assignment → Electronic Catalogue of Original Parts

18 -	Thrust washer

19 -	Inner ring

q	for cylindrical-roller bearing

q	pull off with 4th gear sliding gear → Fig.

q	pressing on → Fig.

20 -

Circlip

q	always replace → Electronic Catalogue of Original Parts

q	Determine thickness → Fig.

21 -	Cylindrical-roller bearing

q	with circlip

q	removing → Fig.

q	pressing on → Fig.

q	Fitting position: the circlip in the bearing points towards the drive shaft

22 -	Clutch housing

q	repairing → Chapter

23 -

Spring

q	on gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are changed (the springs are longer)

q	Fitting position → Fig.

24 -	Sliding sleeve 3rd and 4th gear

25 -	3rd and 4th gear synchronizer body

26 -	Arresters for synchronizer body

q	(3 pieces)

27 -

Spring

q	on gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are changed (the springs are longer)

q	Fitting position → Fig.

28 -	Arresters for synchronizer body

q	(3 pieces)

29 -	5th gear synchronizer body

30 -	5th gear sliding sleeve

31 -	Supporting ring

q	prevents the arresters from wandering

q	removing → Fig.

q	installing → Fig.

Pull out the cylindrical-roller bearing from the clutch housing –  When removing compress circlip -arrow- of the cylindrical-roller bearing with pliers -C-. A -  Countersupport, e.g. -Kukko 22/1- B -  Interior extractor 30 up to 37 mm, e.g. -Kukko 21/5-

Press the cylindrical-roller bearing into the clutch housing –  Support the clutch housing by positioning pipe section -MP3-450 (VW 415 A)- (not visible in figure) directly under the bearing support. –  When inserting compress circlip -arrow- of the cylindrical-roller bearing with pliers -A-. –  Remove pliers before the cylindrical-roller bearing is in fitting position. The circlip must lock into the clutch housing slot.

Press out the bearing support for grooved ball bearing –  Move the sliding sleeve for 1st and 2nd gear to 2nd gear. –  Slide the pressure plate -T10084A- sideways up to stop onto the drive shaft. –  Insert centering pins in pressure plate -T10081- in the holes of the drive shaft and output shaft.   Note Always replace bearing support for grooved ball bearing.

Remove the bushingof the cylindrical-roller bearing with the 4th gear sliding gear –  Removing the circlip. –  Insert separating device -A- behind the running gearing (not the engaging gearing) of the 4th gear and press off. A -  Separating device 12 to 75 mm, e.g. -Kukko 17/1-

Install the bushing of the cylindrical-roller bearing/4th gear sliding gear –  Partly pressing on bushing -A-. –  Position cylindrical-roller bearing -Pos. 17- and 4th gear sliding gear. –  Press down sleeve -A- with thrust washer -Pos. 18- and inner ring/cylindrical-roller bearing -Pos. 19-.

Press off sliding sleeve with 3rd and 4th gear synchronizer body –  After removing the circlip jointly press off the 3rd gear sliding gear and the sliding sleeve/synchronizer body.

Disassembling and assembling the sliding sleeve/3rd and 4th gear synchronizer body 1 -  Spring (as of production date 06.09 the springs are longer) → Electronic Catalogue of Original Parts 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arresters for synchronizer body –  Slide the sliding sleeve over the synchronizer body. The deeper recesses -arrow A- of the arresters in the synchronizer body and the recesses -arrow B- in the sliding sleeve must be positioned above one another.

Assembling the sliding sleeve/3rd, 4th and 5th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. –  Insert the arresters in the deeper recesses -arrows- and mount the springs by turning them 120°.    The angled end of the springs must grip into the hollow arrester of the synchronizer body.

Fitting position of the sliding sleeve/3rd and 4th gear synchronizer body The groove on the front side -arrow- points towards the 4th gear.

Check 3rd, 4th and 5th gear synchronizer rings for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.

3rd, 4th and 5th gear	Fitting dimension	Wear limit
Clearance -a-	1.1 to 1.7 mm	0.5 mm

Press on the synchronizer body with the 3rd and 4th gear sliding sleeve

Press on the inner ring -A- for the cylindrical-roller bearing –  Insert the circlip.

Determining the circlip thickness –  Insert circlip with a thickness of 2.0 mm in the slot of the drive shaft and push upwards. –  Measure the dimension between the inner ring of the taper roller bearing and the positioned circlip using a feeler gauge. –  Remove the circlip used to take the measurement. –  Determine thickness of circlip according to the table.   Note Assign the circlips via the → Electronic catalogue of original parts. The following circlips are available:

Measured value (mm)	Circlip thickness (mm)	Axial play (mm)
0,05…0,14	2,0	0,05…0,15
0,15…0,24	2,1	0,05…0,15
0,25…0,34	2,2	0,05…0,15
0,35…0,44	2,3	0,05…0,15
0,45…0,51	2,4	0,05…0,10

Press the bearing support for grooved ball bearings onto the input and output shafts   Note

t  The drive shafts of the individual gearboxes have different lengths due to the different heights of the serration, dimension -a-. t  In order to press in the bearing support evenly onto the shafts, it is necessary that the shafts are also positioned evenly on the insert base -T10083-. t  A 3 mm thick washer -T10083/1- must be inserted in the fastening opening of the drive shaft, if necessary → Fig.. t  Therefore, the dimension -a- of the output shaft serration must be measured. l  Dimension -a- = 30.6 mm

Insert washer -T10083/1-

Press on the bearing support for grooved ball bearing –  Before pressing on the bearing support heat it to approximately 100 °C.

Press on the bushing -A- for the 5th gear needle bearing

Remove supporting ring –  Unclip the hook -A- of the supporting ring from the synchronizer body with a screwdriver.

Disassembling and assembling the sliding sleeve/5th gear synchronizer body 1 -  Spring (as of production date 06.09 the springs are longer) → Electronic Catalogue of Original Parts 2 -  Arresters for synchronizer body 3 -  Synchronizer body, fitting position: the groove on the front side -arrow A- and the wide collar -arrow B- point towards the 5th gear. 4 -  Sliding sleeve 5 -  Supporting ring –  Slide the sliding sleeve over the synchronizer body.    The deeper recesses -arrow C- of the arresters in the synchronizer body and the recesses -arrow D- in the sliding sleeve must be positioned above one another. –  Insert the arresters in the deeper recesses and mount the springs by turning them 120°.    The angled end of the springs must grip into the hollow arrester of the synchronizer body.

Install supporting ring –  Place the supporting ring onto the flywheel type belt pulley fitting tool -MP9-400-. –  Insert the supporting ring together with the fitting tool in the synchronizer body/5th gear sliding sleeve (Observe fitting position → Fig.). Lock the hooks -arrow 1- in the recesses -arrow 2- of the synchronizer body arresters. –  Push the supporting ring down until the hooks click into position.