Skoda Workshop Service and Repair Manuals

Disassembling and assembling the secondary shaft Special tools and workshop equipment required t  Drive bushing -MP1-316 (30-100)- t  Drift -MP3-403 (VW 295)- t  Pressure plate -MP3-406 (VW 401)- t  Thrust piece -MP3-408 (VW 412)- t  Multi-purpose tool -MP3-419 (VW 771)- t  Drive bushing -MP3-427 (40-21)- t  Pipe section -MP3-429 (2010)- t  Thrust piece -MP3-448 (VW 408A)- t  Pipe section -MP3-461 (VW 519)- t  Pipe -MP3-472 (3118)- t  Thrust piece -MP6-405 (VW 411)- t  Ejector -3138- t  Drawing ring -T30036/3 (2003/3)- t  Thrust plate -T30045 (3005)- t  Pressure washer -T30047 (3062)- t  Guide bushing -T30075 (3039)- t  Separating device 22...115 mm, e.g. -Kukko 17/2- t  Hot-air blower

t	When installing new pinions or drive shaft observe the technical data → Chapter.

t	In case of replacement of the parts marked with 1) the adjustments need to be made. Setting overview → Chapter.

1 -	Gearbox housing

q	repairing → Chapter

2 -	Adjusting washer S3

q	Setting overview → Chapter

3 -	Outer ring/taper roller bearing, large1)

q	removing → Fig.

q	installing → Fig.

4 -	Secondary shaft1)

q	is paired with the crown wheel - if replacing, replace both

q	Adjusting the secondary shaft and crown wheel → Chapter

5 -	Inner ring/taper roller bearing, large1)

q	pressing off → Fig.

q	pressing on → Fig.

6 -	4th gear pinion

q	pressing off → Fig.

q	pressing on → Fig.

7 -	Spacer sleeve

8 -	3rd gear pinion

q	press off together with inner ring Pos. 9 → Fig.

q	pressing on → Fig.

9 -	Inner ring for needle bearing

q	for 2nd gear sliding gear

q	press off together with 3rd gear pinion Pos. 8 → Fig.

q	pressing on → Fig.

10 -	Needle bearing

q	for 2nd gear sliding gear

q	lubricate with gear oil before installing

11 -	2nd gear sliding gear

q	before installing, insert spring Pos. 12 and push needle bearing Pos. 10 onto secondary shaft

12 -

Spring

q	insert in the 2nd gear sliding gear Pos. 11 → Fig.

q	Assignment to sliding gear → Electronic Catalogue of Original Parts

13 -	2nd gear synchronizer ring

q	coated with molybdenum

q	check for wear → Fig.

14 -	Synchronizer body for 1st and 2nd gear

q	pressing off → Fig.

q	pressing on → Fig.

15 -	Sliding sleeve for 1st and 2nd gear

q	Fitting position: groove for selector rod facing towards 1st gear sliding gear Pos. 20

16 -	Inner ring for needle bearing

q	for 1st gear sliding gear

q	pressing off → Fig.

q	pressing on → Fig.

17 -	Needle bearing

q	for 1st gear sliding gear

q	lubricate with gear oil before installing

18 -	1st gear synchronizer ring

q	check for wear → Fig.

19 -

Spring

q	insert in the 1st gear sliding gear Pos. 20 → Fig.

q	Assignment to sliding gear → Electronic Catalogue of Original Parts

20 -	1st gear sliding gear

21 -	Inner ring/taper roller bearing, small1)

q	pressing off → Fig.

q	pressing on → Fig.

22 -

Circlip

q	Determining thickness again → Chapter

23 -	Outer ring/taper roller bearing, small1)

q	extracting → Fig.

q	installing → Fig.

24 -	Adjusting washer S4

q	Setting overview → Chapter

25 -	Bearing shield1)

q	repairing → Chapter

26 -	6th gear pinion

q	pressing off and on → Chapter

q	Fitting position: collar points towards inner ring/tapered-roller bearing small

27 -

Circlip

q	Determining thickness again → Chapter

28 -	5th gear pinion

q	xtracting and inserting → Chapter

29 -

Circlip

30 -

Cover

q	repairing → Chapter

Removing large outer ring/tapered-roller bearing Thrust washer -T30047 (3062)- lies with the graduated side on the outer ring.

Inserting the large outer ring/tapered-roller bearing into the gearbox housing and pressing down –  Heat the gearbox housing with the hot-air blower in the area of the bearing assembly, to about 100°C for around 15 minutes. –  Insert the outer ring in the heated gearbox, and press in under the workshop press until heat is transferred.

Pressing off the small inner ring/taper roller bearing with 1st gear sliding gear A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing off 2nd gear sliding gear with sliding sleeve/synchronizer body for 1st and 2nd gear and inner ring for needle bearing/1st gear sliding gear A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing off 3rd gear pinion with inner ring for needle bearing/2nd gear sliding gear A -  Separating device 22...115 mm, e.g. -Kukko 17/2-

Pressing out 4th gear pinion A -  Separating device 22...115 mm, e.g. -Kukko 17/2-   Note The 4th gear pinion can also be pressed off together with 3rd gear pinion and inner ring for needle bearing/3rd gear sliding gear

Pressing off large inner ring/tapered-roller bearing A -  Separating device 22...115 mm, e.g. -Kukko 17/2- The bearing is destroyed by removing

Pressing on large inner ring/tapered-roller bearing –  Heat inner ring to around 100 °C and mount. –  Press down till there is no axial play.

Pressing on 4th gear pinion –  Heat pinion to around 100 °C, place in position and press on.    Fitting position: Collar towards 3rd gear pinion.

Pressing on 3rd gear pinion –  Mount spacer sleeve -arrow-. –  Heat 3rd gear pinion to approx. 100 °C, mount, and press down.    Fitting position: Collar towards 4th gear pinion.

Pressing on inner ring -A- for needle lager/ 2nd gear sliding gear –  Heat inner ring to around 100 °C and mount. –  Press down till there is no axial play.

Insert spring in sliding gear The looped end of the spring -arrow- must engage in the hole in the sliding gear.

Check synchronizer ring for wear –  Press synchronizer ring into sliding sleeve and measure the size of gap -a- with a feeler gauge at positions -A-, -B- and -C-. –  Add up the measurements and divide by 3. The resulting value should not be less than 0.5 mm.

Mounting 2nd gear sliding gear, pressing on 1st and 2nd gear synchronizer body –  Lubricate needle bearing. –  Mount the needle bearing, sliding gear with spring, and synchronizer ring for 2nd gear. –  Heat inner synchronizer body to around 100 °C and mount. Fitting position: Level hub with 2nd gear sliding gear. –  Press down till there is no axial play. –  Mount sliding sleeve for 1st and 2nd gear.

Pressing on inner ring -A- for needle bearing/ 1st gear sliding gear –  Heat inner ring to around 100 °C and mount. –  Press down till there is no axial play.

Press on small inner ring/tapered-roller bearing –  Lubricate needle bearing. –  Mount the needle bearing, sliding gear with spring, and synchronizer ring for 1st gear. –  Heat inner ring to around 100 °C and mount. –  Press down till there is no axial play.

Extracting small outer ring/tapered-roller bearing

Pressing in small outer ring/tapered-roller bearing –  Place washer S4 in the bearing pedestal in the bearing bracket. –  Press in outer ring for small tapered-roller bearing till it reaches the stop.