Skoda Workshop Service and Repair Manuals

Disassembling and assembling the drive shaft Special tools and workshop equipment required t  Bushing -MP1-316 (30-100)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-408 (VW 412)- t  Pipe section -MP3-414 (VW 516)- t  Pressure spindle -MP3-423 (VW 407)- t  Thrust piece -MP3-431 (3002)- t  Pipe section -MP3-450 (VW 415A)- t  Pipe section -MP3-451 (VW 422)- t  Distance sleeve -MP3-458/2 (VW 472/2)- t  Flywheel type belt pulley fitting tool -MP9-400- t  Cap -T10080- t  Thrust piece -T10081- t  Insert base -T10083- t  Washer -T10083/1- t  Pressure plate -T10084A- t  Cap -T30066 (30-23)- t  Separating device 12...75 mm, e.g. -Kukko 17/1- t  Extractor, e.g. -Kukko 18/1- t  Interior extractor 30...37 mm, e.g. -Kukko 21/5- t  Countersupport, e.g. -Kukko 22/1-

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

t	Insert all bearings, sliding gears and synchronizer rings onto the drive shaft with gear oil.

t	Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.

1 -

Screw

q	removing and installing → Chapter

2 -	Inner ring/cylindrical-roller bearing

q	combined with thrust washer Pos. 3 on some gearboxes → Chapter

q	identify before removing

q	do not interchange with inner ring/cylindrical-roller bearing of output shaft

q	can be replaced separately

q	removing and installing → Chapter

3 -	Thrust washer

q	combined with inner ring/cylindrical-roller bearing Pos. 2 on some gearboxes → Chapter

4 -	6th gear sliding gear

q	No. of teeth → Chapter

5 -	6th gear synchronizer ring

q	check for wear → Fig.

6 -	Needle bearing

q	for 6th gear

q	replace together with Pos. 7

q	on certain gearboxes two-piece, assign via the → Electronic Catalogue of Original Parts

7 -

Bushing

q	for 6th gear needle bearing

q	replace together with Pos. 6

q	removing and installing → Chapter

8 -	Sliding sleeve with 5th and 6th gear synchronizer body

q	removing and installing → Chapter

q	disassembling → Fig.

q	Assembly of the sliding sleeve/5th/6th °gear synchronizer body → Fig. and → Fig.

q	Fitting position → Fig.

9 -	5th gear synchronizer ring

q	is damaged by the drive shaft when removing

q	always replace → Electronic Catalogue of Original Parts

q	check for wear → Fig.

10 -	5th gear sliding gear

q	No. of teeth → Chapter

11 -	Needle bearing

q	for 5th gear

q	replace together with Pos. 12

12 -

Bushing

q	for 5th gear needle bearing

q	replace together with Pos. 11

q	press off with bearing support/grooved ball bearing Pos. 14

q	pressing on → Fig.

13 -	Gearbox housing

q	repairing → Chapter

14 -	Bearing support with grooved ball bearing

q	Always replace grooved ball bearing together with the bearing support

q	If the bearing support is released from the gearbox housing, it must always be replaced → Electronic Catalogue of Original Parts

q	pressing off with 5th°gear pinion → Fig.

q	pressing on → Fig.

15 -	Drive shaft

q	Clean the threaded hole in the drive shaft e.g with a thread tap from the locking agent residues

16 -	Needle bearing

q	for 3rd gear

17 -	3rd gear sliding gear

q	No. of teeth → Chapter

18 -	3rd gear synchronizer ring

q	check for wear → Fig.

19 -	Sliding sleeve with 3rd and 4th gear synchronizer body

q	press off with 3rd gear sliding gear → Fig.

q	disassembling → Fig.

q	Fitting position sliding sleeve/synchronizer body → Fig.

q	assembling → Fig.

q	pressing on → Fig.

20 -

Bushing

q	for 4th gear needle bearing

q	replace together with Pos. 21

q	press off with 3rd gear sliding gear → Fig.

q	pressing on → Fig.

21 -	Needle bearing

q	for 4th gear

q	replace together with Pos. 20

22 -	4th gear synchronizer ring

q	check for wear → Fig.

23 -	4th gear sliding gear

q	No. of teeth → Chapter

24 -	Thrust washer

25 -	Inner ring/cylindrical-roller bearing

q	pressing off → Fig.

q	pressing on → Fig.

26 -

Circlip

q	replace → Electronic Catalogue of Original Parts

q	Determine thickness → Fig.

27 -	Cylindrical-roller bearing

q	with circlip

q	removing → Fig.

q	pressing on → Fig.

q	Fitting position: the circlip in the bearing points towards the drive shaft

28 -	Clutch housing

q	repairing → Chapter

29 -

Spring

q	Fitting position → Fig.

30 -	Sliding sleeve 3rd and 4th gear

31 -	3rd and 4th gear synchronizer body

32 -	Arresters (3 pieces)

33 -

Spring

q	Fitting position → Fig.

34 -	Arresters (3 pieces)

35 -	Synchronizer body for 5th and 6th gear

36 -	Sliding sleeve 5th and 6th gear

Pull out the cylindrical-roller bearing from the clutch housing –  When removing compress circlip -arrow- of the cylindrical-roller bearing with pliers -C-. A -  Countersupport, e.g. -Kukko 22/1- B -  Interior extractor 30...37 mm, e.g. -Kukko 21/5-

Press the cylindrical-roller bearing into the clutch housing –  Support the clutch housing with pipe section -MP3-450 (VW 415A)-, not visible in figure, directly under the bearing support. –  When inserting compress circlip -arrow- of the cylindrical-roller bearing with pliers -A-. –  Remove pliers before the cylindrical-roller bearing is in fitting position. The circlip must lock into the clutch housing slot.

Press off the bearing support with the grooved ball bearing and the 5th gear° pinion -A- –  Sliding sleeve for 1st and 2nd gear to 2nd gear. –  Slide the pressure plate -T10084 A- sideways up to stop onto the drive shaft.   Note Always replace bearing support with grooved ball bearing → Electronic Catalogue of Original Parts.

Press off inner ring/cylindrical-roller bearing –  Removing the circlip. –  Press off inner ring for cylindrical-roller bearing together with thrust washer, 4th °gear sliding gear with needle bearing, sliding sleeve/synchronizer body for 3rd °and 4th °gear and 3rd °gear sliding gear.

Disassembling and assembling the sliding sleeve and 3rd and 4th gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arresters for synchronizer body –  Slide the sliding sleeve over the synchronizer body. The deeper recesses -arrow A- of the arresters in the synchronizer body and the recesses -arrow B- in the sliding sleeve must be positioned above one another.

Assembly of the sliding sleeve/3rd and 4th gear synchronizer body l  The sliding sleeve is drawn over the synchronizer body. –  Insert the arresters in the deeper recesses -arrows- and mount the springs with 120° offset.    The angled end of the springs must grip into the hollow arrester of the synchronizer body.

Fitting position of the sliding sleeve/3rd and 4th gear synchronizer body The groove on the front side -arrow- points towards the 4th gear.

Check synchronizer ring for wear –  Press the synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.

Clearance -a-	Fitting dimension	Wear limit
3., 4, 5 and 6th gear	1,1 … 1.7 mm	0.5 mm

Press on the synchronizer body with the 3rd and 4th gear sliding sleeve Fitting position: The wide collar points to the 3rd gear sliding gear.

Press on the bushing -A- for the 4th °gear needle bearing –  Subsequently place 4th gear needle bearing with 4th gear sliding gear and thrust washer.

Press on the inner ring -A- for the cylindrical-roller bearing –  Insert determined circlip → Fig..

Determining the circlip –  Insert circlip -A- with a thickness of 2.0 mm in the slot of the drive shaft and push upwards -arrow-. –  Measure dimension between inner ring -B- and positioned circlip -A- using a feeler gauge -C-. –  Remove the circlip used to take the measurement. –  Determine the first circlip required according to the table.   Note Assign circlips via → Electronic Catalogue of Original Parts. Circlips available

Measured value (mm)	Circlip thickness (mm)	Axial play (mm)
0,05…0,14	2,0	0,05…0,15
0,15…0,24	2,1	0,05…0,15
0,25…0,34	2,2	0,05…0,15
0,35…0,44	2,3	0,05…0,15
0,45…0,51	2,4	0,05…0,10

Press the bearing support for grooved ball bearings onto the input and output shafts   Note

t  The drive shafts of the individual gearboxes have different lengths due to the different heights of the serration, dimension -a-. t  In order to press in the bearing support evenly onto the shafts, it is necessary that the shafts are also positioned evenly on the insert base -T10083-. t  A 3 mm thick washer -T10083/1- must be inserted in the fastening opening of the drive shaft, if necessary → Fig.. t  Therefore, the dimension -a- of the output shaft serration must be measured. l  Dimension -a- = 30.6 mm

Insert washer -T10083/1-

Press on bearing support with grooved ball bearing –  Before pressing on the bearing support heat it to max. 100 °C.   WARNING Wear protective gloves!

Press on the bushing -A- for the 5th gear needle bearing

Disassembling and assembling the sliding sleeve and 5th/6th gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arrester –  Slide the sliding sleeve over the synchronizer body. The deeper recesses -arrow A- of the arresters in the synchronizer body and the recesses -arrow B- in the sliding sleeve must be positioned above one another.

Assembly of the sliding sleeve/5th/6th °gear synchronizer body l  The sliding sleeve is drawn over the synchronizer body. –  Insert the arresters in the deeper recesses -arrows- and mount the springs with 120° offset. l  The angled end of the spring must grip into the hollow arrester.