Skoda Workshop Service and Repair Manuals

Repairing gearbox housing Special tools and workshop equipment required t  Drive bushing -MP3-402 (VW 244B)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Multi-purpose tool -MP3-419 (VW 771)- t  Thrust piece -MP3-420 (3124)- t  Pressure spindle -MP3-423 (VW 407)- t  Guide piece -MP3-454 (VW 439)- t  Pipe section -MP3-4012 (VW 416B)- t  Gearbox mount -T30027 (VW 801)- t  Guide bolt -T30074 (10 - 15)- t  Mandrel -T30083 (3264)- t  Assembly device -T30100 (3290)- t  Drift -T10168- t  Drift -T10169- or Drift -T10362- → Fig. t  Thrust piece -T10203- t  Interior extractor, e.g. -Kukko 21/2- t  Interior extractor, e.g. -Kukko 21/4- t  Countersupport e.g. -Kukko 22/2 -

Removing cap -A- –  Push the rubber through the middle of the cap using a screwdriver -B- and lever out the cap -direction of arrow-.

Drive in cap up to the stop

Removing locking angle for gearshift shaft –  Remove angle in the released position. –  Insert a screwdriver -A- in the hole of the locking angle -B-. –  Lever out inner part of locking angle in -the direction of the arrow-.

Fitting position of locking angle –  The marking on the locking angle -arrow- must point to the connection of the slave cylinder -1-. The dimension -a- must be approx. 45°.

Drive in locking angle -arrow- for gearshift shaft up to the stop of the tool   Note Locking angle must be released during drive-in procedure.

Remove bushing for gear shift rod A -  Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2 - B -  Countersupport, e.g. -Kukko 22/2-   Note After removing the bushing check for damage, if necessary replace.

Drive in the bushing for the shift rod up to the stop of the tool

Press serrated sleeve -A- out of gearbox housing –  Position the gearbox housing on the pressure plates -MP3-406- and -MP3-407- in such a way that the dowel sleeves in the gearbox housing are not damaged.

Drive out serrated sleeve without disassembling gearbox with guide bolts -T30074- –  First remove locking screw and gearshift shaft. –  Turn the gearbox in such a way that the serrated sleeve does not fall into the gearbox.

Difference between serrated sleeves A serrated sleeve can be fitted with shoulder -arrow 1- → Fig. and without shoulder -arrow 2- → Fig.. Assign components via the → Electronic catalogue of original parts.

Drive in serrated sleeve up to the stop of the tool A -  Drive in serrated sleeve with shoulder, drift -T10169-. B -  Drive in serrated sleeve without shoulder, drift -T10362-. l  Gearbox housing screwed to clutch housing.

Pull needle bushing for reverse shaft out of the gearbox housing A -  Interior extractor 23.5...30 mm, e.g. -Kukko 21/4- B -  Countersupport, e.g. -Kukko 22/2-   Note The needle bushing is damaged when removed and must be replaced.

Pressing in needle bushing -A- in the gearbox housing –  During press-in procedure, position the thrust washer -A- of the reverse shaft onto the needle bushing. –  Support the gearbox housing with a pipe section -MP3-4012- directly below the bearing support.

Remove bushing for gearshift shaft –  Hold spindle of assembly device -T30100- and turn nut -B-. A -  Interior extractor 14.5...18.5 mm, e.g. -Kukko 21/2-

Drive in the bushing -A- for the gearshift shaft up to the stop of the tool.

Driving in plug –  Drive in plug -1- with the mandrel -T30083- to the dimension -a- = approx. 3 mm below the upper edge of the housing.