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  Filling capacity → Chapter. Gaskets, seals On separator surfaces with paper gasket: t  Replace paper gasket. On separator surfaces with sealant: t  Clean contact surfaces thoroughly and apply sealant -AMV 188 001 02-. t  Apply sealant evenly - 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 location: 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 for tapered-roller bearing on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 100°C for installing. When assembling, press up to the stop until there is no axial play. t  Heat the inner rings for needle and roller bearing on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 100°C for installing. 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  Grease needle bearings for gearbox drive shaft in flywheel. 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, and replace if necessary. t  Insert moist with some gearbox fluid. Gear pinions and synchronizer body t  Clean and heat on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 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 tube-hose line. t  If the slave cylinder with connected tube-hose 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.