Repairing the gearbox housing

Make

Skoda

Model

Superb

Section

Gearbox 0A2 › Gearbox mechanics,operation, construction,diff. › Repairing the gearbox housing

Power transmissionRepairing 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.

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..

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°.

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.

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°.

Fitting dimension of ventilation pipe Dimension -a- = 16.8 mm

Pulling out gasket ring for gearshift shaft with gearbox disassembled –  Carefully lever out gasket ring with a screwdriver.

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-

Drive in ball sleeve for gearshift shaft l  Insertion depth: 8.5 ± 0.5 mm under housing surface.

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.

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.

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.

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-

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)-.

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.

06 Transmission