Skoda Workshop Service and Repair Manuals

Disassembling and assembling the output shaft Special tools and workshop equipment required t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Pressure spindle -MP3-423 (VW 407)- t  Drive bushing -MP3-427 (40-21)- t  Pipe section -MP3-450 (VW 415A)- t  Thrust piece -MP3-4014 (VW 432)- t  Interior extractor 30...37 mm, e.g. -Kukko 21/5- t  Countersupport, e.g. -Kukko 22/1-

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

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

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

1 -	Clutch housing

q	repairing → Chapter

2 -	Cylindrical-roller bearing

q	with circlip

q	removing → Fig.

q	installing → Fig.

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

3 -	Output shaft

q	if an inner ring is fitted as a bearing assembly for the cylindrical-roller bearing Pos. 2, it cannot be removed from the output shaft

q	Inspect bearing assembly or inner ring for cylindrical-roller bearing for scoring and damage

q	Replace output shaft and cylindrical-roller bearing together if there is scoring or damage on the bearing assembly or inner ring

4 -	4th gear pinion

q	Fitting position: the collar points to the 3rd gear → Fig.

q	No. of teeth → Chapter

5 -

Circlip

6 -

Circlip

7 -	3rd gear pinion

q	Fitting position: the collar points to the 4th gear → Fig.

q	No. of teeth → Chapter

8 -

Circlip

9 -	2nd gear sliding gear

q	No. of teeth → Chapter

10 -	Needle bearing

q	for 2nd gear

11 -	Inner ring for 2nd gear

q	check for wear → Fig.

q	Fitting position → Fig.

12 -	Outer ring for 2nd gear

q	place onto the inner ring Pos. 11

q	replace if there are any traces of scoring or friction

q	Fitting position → Fig.

13 -	2nd gear synchronizer ring

q	check for wear → Fig.

q	Fitting position → Fig.

14 -	Sliding sleeve with 1st and 2nd gear synchronizer body

q	after removing the circlip -Pos. 15- press off with the 2nd gear sliding gear → Fig.

q	disassembling → Fig.

q	Assembling sliding sleeve/synchronizer body → Fig. and → Fig.

q	Fitting position → Fig.

q	pressing on → Fig.

15 -

Circlip

q	pushing out → Fig.

q	inserting → Fig.

16 -	1st gear synchronizer ring

q	check for wear → Fig.

q	insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 14

17 -	Outer ring for 1st gear

q	insert into synchronizer ring Pos. 16

q	Fitting position → Fig.

q	replace if there are any traces of scoring or friction

18 -	Inner ring for 1st gear

q	check for wear → Fig.

q	Check pegs for traces of wear

q	Fitting position → Fig.

19 -	Needle bearing

q	for 1st gear

20 -	1st gear sliding gear

q	Fitting position → Fig.

q	No. of teeth → Chapter

21 -	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	removing and installing → Chapter

22 -	Gearbox housing

q	repairing → Chapter

23 -

Screw

q	removing and installing → Chapter

24 -	Inner ring/cylindrical-roller bearing

q	identify before removing

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

q	can be replaced separately

q	removing and installing → Chapter

25 -	6th gear pinion

q	Fitting position: the collar points to the bushing Pos. 26

q	removing and installing → Chapter

q	No. of teeth → Chapter

26 -

Bushing

q	removing and installing → Chapter

27 -	5th gear pinion

q	Fitting position → Chapter

q	press off together with bearing support Pos. 21 → Chapter

q	pressing on → Chapter

q	No. of teeth → Chapter

28 -

Spring

q	Fitting position → Fig.

29 -	Sliding sleeve

30 -	Synchronizer body

31 -	Arresters (3 pieces)

Pull out the cylindrical-roller bearing from the clutch housing –  When removing compress circlip of the cylindrical-roller bearing -arrow- 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-, not visible in figure, directly under the bearing support. –  When pressing in the cylindrical-roller bearing compress the circlip -arrow- with pliers -A-. –  Remove pliers before the cylindrical-roller bearing is in fitting position. The circlip must lock into the clutch housing slot.

Press the circlip -1- out of the slot A -  Protective glove   WARNING Prevent uncontrolled ejection of the circlip.

Press off sliding sleeve with 1st and 2nd gear synchronizer body –  After removing the circlip jointly press off the 2nd gear sliding gear and the sliding sleeve/synchronizer body.

Fitting position of gear pinion of 3rd and gear pinion of 4th –  Place the 4th gear pinion -A- on the output shaft.    Fitting position:    The collar -arrow 1- points towards the 3rd gear pinion -B-. –  Insert circlips -1- and -2-. –  Place the 3rd gear pinion -B- on the output shaft.    Fitting position:    The collar -arrow 2- points towards the 4th gear pinion -A-. –  Insert circlip -3-.

Check 1st and 2nd gear inner ring for wear –  Press the inner ring -2- on the cone of the sliding gear and measure clearance -a- with a feeler gauge -1-.

	Fitting dimension	Wear limit
Clearance -a-	0,75 … 1,25 mm	0.3 mm

Check 1st and 2nd gear synchronizer ring for wear –  Press the synchronizer ring, outer ring and inner ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge -1-.

	Fitting dimension	Wear limit
Clearance -a-	1,2 … 1,8 mm	0.5 mm

Fitting position of the outer ring, inner ring and 2nd gear synchronizer ring –  Position the inner ring -A- on the 2nd gear sliding gear.    The angled lands -arrow 1- point towards the outer ring -B-. –  Position the outer ring -B-.    Lock the lands -arrows 2- in the recesses -arrows 3- of the sliding gear. –  Insert the synchronizer ring -C-.    Lock the recesses -arrows 4- in the lands -arrows 1- of the inner ring -A-.

Disassembling and assembling the sliding sleeve and 1st and 2nd gear synchronizer body 1 -  Spring 2 -  Sliding sleeve 3 -  Synchronizer body 4 -  Arresters for synchronizer body –  Slide the sliding sleeve over the synchronizer body. Fitting position: After assembly the groove on the front side -arrow A- and the higher collar -arrow B- of the synchronizer body point towards the outer serration of the sliding sleeve -arrow C-. The deeper recesses -arrow D- of the arresters in the synchronizer body and the recesses -arrow E- in the sliding sleeve must be positioned above one another.

Assembly of the sliding sleeve/1st and 2nd 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 spring must grip into the hollow arrester.

Press on the sliding sleeve and 1st and 2nd gear synchronizer body Fitting position: The slot for the shift fork in the sliding sleeve points towards the 1st gear, the serration of the reversing gear points towards the 2nd gear. –  Rotate the synchronizer ring in such a way that the slots are flush with the arresters.

Insert the circlip –  Insert the 1st gear synchronizer ring in the sliding sleeve/synchronizer body.

Fitting position of the 1st gear outer ring The pegs -arrows- point towards the reversing gear serration.

Fitting position for 1st gear inner ring -A- Lock the pegs -arrows 1- in the recesses -arrows 2- of the synchronizer ring -B-.

Fitting position 1st gear sliding gear The higher collar -A- points towards the 2nd gear -B-. The recesses in the collar -arrows- lock into the pegs of the outer ring → Fig..