Skoda Workshop Service and Repair Manuals

Components Gearbox t  When installing the gearbox, ensure the dowel sleeves are correctly located between the engine and gearbox. t  When assembling mounts as well as waxed components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease. t  Bolts and other attachments should have a classification in the → Electronic Catalogue of Original Parts. t  When replacing the manual gearbox check the oil level and if necessary top up with oil → Chapter. t  Capacity and specification → Chapter. Gaskets, seals t  Clean contact surfaces thoroughly and apply sealant -AMV 188 001 02-. t  Apply sealant evenly, and not too thickly. t  Replace O-rings → Electronic Catalogue of Original Parts. t  Replace radial shaft seals → Electronic Catalogue of Original Parts. –  Before installing:

Lightly oil the outer diameter and pack half the space between the sealing lips -arrow- with the sealing grease -G 052 128 A1-. –  After installing: Inspect the gear oil level in the gearbox → Chapter. Locking elements t  Do not over-tension the circlips. t  Always replace damaged or over-tensioned circlips → Electronic Catalogue of Original Parts. t  Circlips must be positioned in the base of the groove.

t  Replace roll pins. Fitting position: slot longitudinally to power flow. Screws, nuts t  Slacken and tighten nuts and bolts for attaching covers and housings diagonally across. t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across in stages. t  Tightening torques apply for non-oiled nuts and bolts. t  Always replace the self-locking screws and nuts → Electronic Catalogue of Original Parts. t  It is important to ensure at all bolted connections that the contact surfaces as well as the nuts and bolts are waxed only after being installed, should this be necessary. t  Clean all threaded holes into which self-locking bolts are inserted, with a thread tap to remove residues of the locking fluid. Otherwise there is a risk that the bolts will shear at the next disassembling. Bearings t  Position needle bearing, ball sleeves and roller sleeves with the lettered side (thicker end) towards the drift pin. t  New taper roller bearings are fitted as supplied and do not require any additional lubrication. t  Insert all bearings (except tapered-roller bearing) in the gearbox with gear oil. t  Heat the inner rings of the tapered-roller bearing to approx. 100°C for installing, press up to the stop until there is no axial play when assembling. t  Heat the inner rings for needle and roller bearing to maximum 130°C. t  Do not exchange the outer and inner rings of bearings of the same size - bearings go in pairs. t  Jointly replace tapered-roller bearings on the same shaft and use products of the same manufacturer. t  Check the double angular ball bearing → Chapter with the secondary shaft fitted and the differential removed for wear (running noises). “When turning the secondary shaft, the bearing must not hook or run rough”. t  If the drive chain was replaced or metal swarf is found in the engine oil, then the double angular ball bearing on the secondary shaft must always be replaced. Shims t  Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely. t  Inspect for burrs and damage. t  Install only undamaged shims which are in perfect condition. Synchronizer rings t  These are not interchangeable. If re-using, allocate synchronizer rings to the same gear. t  Inspect for wear, replace if necessary → Electronic Catalogue of Original Parts.

t  Check the coated friction surfaces -arrows 2- of the intermediate ring -B- for damage (position the plate, cracking of carbon coating). t  Inspect the inner friction surface -arrow 1- of the synchronizer ring -A- and the outer friction surface -arrow 4- of the inner ring -C- for traces of “scoring” and “friction”. t  For inner rings -C- with coated friction surface -arrow 3- check the coating for damage (cracking of carbon coating). t  Insert moist with some gearbox fluid. Gear pinions and synchronizer body t  Clean and heat on a heating plate max. 100°C before pressing on. t  When assembling, press up to the stop until there is no axial play. t  Check fitting position. Sliding gears t  Check 1st to 6th gear sliding gears after assembly for low axial play of 0.10 mm or for smooth operation. Damage to sliding gears or sliding sleeves

t  Damage to synchronizer ring or sliding gear: A -  Worn tooth pointing of the clutch gearing (engaging gearing) to synchronizer ring or sliding gear.

t  To compare: Synchronizer ring or sliding gear undamaged: B -  Undamaged tooth pointing of the clutch gearing (engaging gearing) to synchronizer ring or sliding gear.

t  Damage to the sliding sleeve: C -  Worn tooth pointing of the longitudinal internal serration to the sliding sleeve.

t  To compare: Sliding sleeve undamaged: D -  Undamaged tooth pointing of the longitudinal internal serration to the sliding sleeve. Clutch control t  When removing gearbox, remove slave cylinder, do not detach the hoses. t  If the slave cylinder with connected hydraulic line is removed, do not depress the clutch pedal. Otherwise the tappet is pressed out of the slave cylinder. t  If the clutch pedal does not return to the off position after the coupling procedure, check the function of master and slave cylinder → Chapter. t  Do not tilt the clutch pressure plate, release or tighten in small stages crosswise t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch bell (gearbox housing) as well as the flywheel and the engine on the side of the gearbox. t  Assembly instructions for the SAC pressure plate → Chapter.