skoda Workshop Repair Guides

Skoda Workshop Service and Repair Manuals

Gearbox,mechanics,gears,shafts,internal operation > < Repairing gearbox cover
Repairing the gearbox housing
Repairing the gearbox housing
Special tools and workshop equipment required
t  Drive bushing -MP1-316 (30-100)-
t  Drift -MP3-403 (VW 295)-
t  Adapter -MP3-403/1 (VW 295A)-
t  Multi-purpose tool -MP3-419 (VW 771)-
t  Pipe section -MP3-479 (VW 423)-
t  Insertion tube -MP3-485 (32-109)-
t  Assembly device -MP6-414 (3253)-
t  Retaining plate -T30027 (VW 801)-
t  Locking pin -T30044 (2064)-
t  Guide bolt -T30074 (10-15)-
t  Straightedge -T40100-
t  Interior extractor -3275-
t  Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
t  Countersupport, e.g. -Kukko 22/1-
t  Countersupport, e.g. -Kukko 22/2-
t  Depth gauge
   
  Note
On certain gearboxes, bushings for shift rods are installed instead of ball sleeves Pos. 15 to 18. Remove these bushings → Fig.. Drive in bushings with locking pin -T30044 (2064)- up to the stop. The gearbox housing was modified in combination with the bushings. Assign components via the → Electronic catalogue of original parts.
1 - Needle bushing
q   for drive shaft
q   always replace → Electronic Catalogue of Original Parts
q   removing → Fig.
q   inserting → Fig.
q   measuring insertion depth → Fig..
q   after installing, secure by caulking → Fig.
2 - Ball sleeve
q   for gearshift shaft
q   removing → Fig.
q   driving in and securing → Fig.
3 - Cap
q   for gearbox bleeder
4 - Ventilation tube
q   Fitting dimension → Fig.
q   clip on cap Pos. 3 for gearbox bleeder
5 - Gearbox housing
q   if replaced: Deterime positioning for 2nd gear sliding gear again → Chapter, setting secondary shaft and differential (drive chain) → Chapter
q   modified in combination with bushings for shift rods, assign via → Electronic Catalogue of Original Parts
6 - Ball sleeve
q   for gearshift shaft
q   removing → Fig.
q   inserting → Fig.
7 - Gasket for gearshift shaft
q   can be replaced if removing (not disassembling) the gearbox → Chapter
q   always replace → Electronic Catalogue of Original Parts
q   removing → Fig.
q   inserting → Fig.
q   only mount with assembling sleeve on fitted gearshift shaft → Chapter
8 - Right outer ring/tapered-roller bearing
q   for differential
q   if replaced: Adjusting the differential gear (crown wheel) → Chapter
q   removing and installing → Chapter
9 - Adjusting washer “S2
q   Note thickness
q   Setting overview → Chapter
10 - Grooved ball bearing
q   for drive shaft
q   remove with gearbox disassembled → Fig.
q   remove with gearbox removed (not disassembled) → Chapter
q   installing → Fig.
11 - Intermediate piece
q   replace if damaged
12 - Oil drain plug - 40 Nm
13 - Gasket ring
q   for right flange shaft
q   replace → Chapter
14 - Magnet
q   cleaning
q   insert into housing rib
15 - Ball sleeve
q   for reverse gear shift rod
q   removing → Fig.
q   inserting → Fig.
q   measuring insertion depth → Fig..
q   Change: on certain gearboxes a bushing is fitted instead of the ball sleeve
16 - Ball sleeve
q   for 1st and 2nd gear shift rod
q   removing → Fig.
q   inserting → Fig.
q   measuring insertion depth → Fig..
q   Change: on certain gearboxes a bushing is fitted instead of the ball sleeve
17 - Ball sleeve
q   for 3rd and 4th gear shift rod
q   removing → Fig.
q   inserting → Fig.
q   measuring insertion depth → Fig..
q   Change: on certain gearboxes a bushing is fitted instead of the ball sleeve
18 - Ball sleeve
q   for 5th and 6th gear shift rod
q   removing → Fig.
q   inserting → Fig.
q   measuring insertion depth → Fig..
q   Change: on certain gearboxes a bushing is fitted instead of the ball sleeve

   
Pull needle bushing for drive shaft out of the gearbox housing
A - Countersupport, e.g. -Kukko 22/2-
–  If present, remove caulking recesses.
  A35-10054
Drive needle bushing for drive shaft into the gearbox housing
Position needle bushing with the lettered side (thicker end) towards the drive bushing -30-100 (MP1-316)-.
Insertion depth of needle bushing → Fig..
  A35-10055
Measure insertion depth of needle bushing and secure needle bushing by caulking
l  Measurement -a- = 88.0 ± 0.5 mm
–  For caulking, use a blunt centre punch with ball-shaped end (5 mmØ ball).
–  The needle bushing is secured -arrows- by 3 caulking markings, offset at circumference by 120°.
  A35-10081
Pull out ball sleeve for gearshift shaft
A - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
–  If present, remove caulking recesses.
  S34-0647
Drive in ball sleeve for gearshfit shaft and secure by caulking
Position ball sleeve with the lettered side (thicker end) towards guide bolt -10-15 (T30074)-.
–  Drive in ball sleeve -1- to the fitting dimension -a- = 1.5 ± 0.5 mm under housing surface.
After driving in, secure ball sleeve by caulking as follows:
–  For caulking, use a blunt centre punch with ball-shaped end.
–  Ball sleeve is secured by 3 caulking markings -b-, offset at circumference by 120°.
  A34-10194
Fitting dimension of ventilation pipe
Dimension -a- = 16.8 mm
  V34-1071
Pulling out gasket ring for gearshift shaft with gearbox disassembled
–  Carefully lever out gasket ring with a screwdriver.
  A34-0650
Pull out ball sleeve for gearshift shaft
First remove gasket ring for gearshift shaft → Fig..
A - Countersupport, e.g. -Kukko 22/1-
B - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
  A34-10191
Drive in ball sleeve for gearshift shaft
l  Insertion depth: 8.5 ± 0.5 mm under housing surface.
  A34-10192
Driving in gasket ring for gearshift shaft
–  Fill half the space between the sealing lip and dust lip with sealing grease -G 052 128 A1-.
–  Lightly lubricate the outer circumference of the gasket ring.
–  Driving in gasket ring -arrow- up to 1.0 ± 0.2 mm under housing surface, at the same time do not tilt.
  S34-0649
Removing grooved ball bearing for drive shaft with gearbox disassembled
–  Position adapter -VW 295A (MP3-403/1)- with small Ø into the grooved ball bearing.
–  Drive out grooved ball bearing.
  A34-10157
Drive in grooved ball bearing for drive shaft up to the stop.
Fitting position:
The closed side of the cage for the balls points to the gearbox housing.
–  Drive grooved ball bearing up to the stop into the gearbox housing.
  A34-10159
Pull out ball sleeve or bushing -C- for shift rod.
A - Countersupport, e.g. -Kukko 22/2-
B - Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-
  A34-10099
Drive in ball sleeve for shift rod
–  Drive in ball sleeve -A- for 5th/6th gear shift rod with locking pin -2064 (T30044)- to the fitting dimension → Fig..
–  Drive in the remaining 3 ball sleeves -B- with guide bolt -10-15 (T30074)- to the fitting dimension → Fig..
Position ball sleeve with the lettered side (thicker end) towards guide bolt -10-15 (T30074)- or locking pin -2064 (T30044)-.
  A34-10168
Insertion depth of ball sleeves in gearbox housing
–  Press in ball sleeve for 5th/6th gear shift rod -1- to the dimension -a- = 143.5 ± 0.5 mm.
–  Press in ball sleeve for 3rd/4th gear shift rod -2- to the dimension -a- = 133.5 ± 0.5 mm.
–  Press in ball sleeve for 1st/2nd gear shift rod -3- to the dimension -a- = 116.5 ± 0.5 mm.
–  Press in ball sleeve for reverse gear shift rod -4- to the dimension -a- = 116.5 ± 0.5 mm.
  Note
Measure from the housing contact surface to the respective ball sleeve with a depth gauge.
  A34-10189

Gearbox,mechanics,gears,shafts,internal operation > < Repairing gearbox cover