1980 SKODA 105S lock

4.8
B
Generr The
i. e., th
ferenti,
togethr
checke (meshi
on ther
Only
crown '
con be
Bevel (
Sporl
with n
trotion
The ;
( 175) vt
like the
first por
froction
the pini
crossing port of I
in hund
missing
Adjustir To od
set the ,
the oxis
the flonl
the MP I
1. Fos
the diol
length
ond depth ond strike
it off while still
hot from grinding.
Co u t io n ! The
iig used
for other types of
Skodo cors connot be
used for removing
this
roce!
Although the ports
ore identicol
ot f irst sight,
the teeth of the pinion
ore lorger ond they
would not poss without
o domoge
through the
iig. When dismontling
the synchronizing
locks,
support the clutch core
with on obiect obout
20 mm high, toke
the lock
between the polms
of both honds, ond pull
it off the core. The bolls
cnd springs
eiected from the co,re
will foll in
your polms.
4.7 DRIVE
SHAFT C/W GEARS
Like the driven shoft, i. e. the pinion
with
geors, the drive shoft with its geors
forms o
unit to be instolled
in the georboi.
For ossemb-
ling the drive
shoft, use
ogoin the work
bench
ond-o press.
When replocing
one of the drive
shoft geors
with o new
one, it is necessory
to
renew olso its meshing geor
on the driven shoft
(pinion).
Assembling Drive Shoft
1. Using o grindstone,
chomfer the shorp
ed-
ges of both geors
ot the point
of their inner
cylindricol bores ond the
loterol
chomfer of
these bores.
. 2.
H,ug-t up the 3rd-speed
geor
to o tempero_
ture of-80 up to 100oC,
insert it
with the longer
side of the inner heod f irst into
the Mp 3-106
support ond shrink-f
it the shoft.'Use
the other
port of the support,
the buttress plote,
slipped
over the sphericol
end of the diive shoit'os
o thrust pod
between the shrink-fitted
shoft
ond the press
spindle.
3. Heot up the 4th-speed
geor
like the previ-
9t1;. geor
ond shrink-fit it on the shoft _
see Fig.
4.7t2.
4. Press the boll beoring
with its outer thrust
ring owoy from the shoft
to the th-speed
geon,
ond onother
boll beoring
to the 1st-sireed
[eor.
Use the other
holf of the Mp 3-106
supporl
for
pressing-on the beorings.
.5. Clomp
the shoft in o vice (providing
the
v.ice iows with sheet
linings)
Uy'the floriks of
the 4th-speed geor
ond tighteh
the nut. Hommer
down the nut neck into
the shoft qroove.
Use o new nut if the neck
of thle
old one is
domoged.
Eliminote ony stress
resulting
from shrinking
on the geors
by topping
the geors
ond the shofl
willr o mollet. Dismontling
Drive Shoft
1. Clomp the shoft in o vice ocross
the foce
of the 4th-speed geor
ond screw off the nut.
Instoll the shoft in the Mp 3-106
support
by the
outer beoring roce ond press
off the beoring.
2. Press the shoft out of the beorings
by
plocing the support
successively
under the
in-
dividuol geors
ond the second beoring. protect
the shoft sphericol
end -
use the buttress plote
for pressing off- see porogroph
2 of the previ-
ous section.
Fig. 4.711 -
Shrink-fitting of Geo,rs on Drive
Shoft Using
MP 3.106 Support (two-port
iig
consisting of the support proper
ond the butt-
ress plote)
Fig.4.712 -
Drive Shoft c/w Geors
- 1st-speed geor,2-
reverse geor, 3 -
2nd-speed
geor, 4 -
3rd-speed geor, 5- 4th-speed geor
88 1-
MP

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b)
Alil 1.
con
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int
Fig.5.2l5
-
Pressing Boll Beoring
on Shoft
Using MP 5-112 Jig ond
lts Liner (smoller)
Fig.5.216 -
Connection of
Holf-oxles
with Rodius Arms
lorger ond one smoller, ond the forked plote),
screw down the
iig on the threod
of the shoft,
ond use
nuts to ottoch it
to the holf-oxle socketf
longe. The
iig of
the lotest design permits
its
simple fostening by engogement with
the holf-
oxle flonge (fit
the
iig ond
rotote
it to lock it
in position).
Instoll the lorger liner between the boll
beor-
irrg ond the
iig heod, ond
press
the boll
beorirrg
on the shoft by turning the iig wrench.
3. Reploce the lorger liner with the smoller
one (rest it ogoinst the
iig bolt heod), ond turn
the wrench in the opposite direction to press
the beoring into the holf-oxle socket.
Fitting Broke Mechonism ond Wheel Hub
4. Instoll the broke bocking plote
complete
with the broke
mechonism on the holf-oxle
socket, slip on the "O"
seoling ring ond the
cop with the seoling ring (with
the tightening
f in focing toword the holf-oxle), ond fosten
oll
the porrts
with bolts, spring woshers, ond
nuts.
The seoling ring should be driven or pressed
into the cop so thot the tightening lip foces the
beoring ond
iust so thot there
remoins
o gop
of
1 to 2 mm between the pocking
ond the cop
f longe.
5. lnsert the key in
the shoftwith its bevelled
end into the runout of the keywoy, smeor
the
hub neck with oil so
thot it does not
drog in
the seoling ring, ond fit the hub with the broke
drum in position.
Moke sure thot the key did
not move further olong the shoft (its
lifted end
in the keywoy would couse the hub to burst)
ond tighten
lightly the nut. Since o high
torque
is required
for finol tightening of the nut, put
off the tightening ond locking of the nut till
ofter instollotion in the cor. Then
tighten the
nut with full torque (see
Chopter 1.8),
top on
the hub to relieve
the possive
stress of the
toper, retighten to the specified torque, ond
lock the nut with o cotter pin.
Fitting Rodius Arms
6. Instoll
the spocer into the rodius
orm, fit
the knurled
woshers (with
the knurling toword
the orm)
to either side of the ellipticol holes of
the rodius
orm, ond fosten them with bolts ond
nuts not
forgetting the spring woshers. Do not
tighten the connection fully. Threod
the bolts
through the bolt holes so thot their nuts foce
into the cor ofter fitting the rodius orm to the
holf-oxle.
Fit the rodius
arm on the protruding
holf-oxle
pin ond threod
the bolt through the hole
of the
secrt. Slip
spocing tubes on the bolt ond pin
together with sheet shims with rubber liners
ond fosten
lightly (without tightening)
the
rodius orm to the holf-oxle using nuts
ond lock
woshers. Tighten
fully the connection
ofter fit-
ting the ossembly
in the cor when odiusting
the
reor wheel
olignment (geometry).
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98

5.5-5.7
the toe-in of the reor
wheels using olso the
MP 8-152 gouge or onother speciol gouge
ovoil-
oble in your
workshop. To
obtoin the required
shift of the holf-oxles (symmetricol
so os not
to
disturb the oxle olignment), strike ogoin the
holf-oxles with o rubber mollet
os per poro-
groph 2.
4" Retighten the slockened connections
(rodius orm bolts) ond, occording to the pro-
gress of the reossembly, olso the nuts of the
holf-oxle shoft (see
Chopter 5.2, porogroph
5).
Complete the operotion by locking the nuts.
Fig. 5.5/3 -
Checking Alignment of Reor Axle
with Cor Centre Line Using MP 8-158
Gouge 5.6 HALF.AXLE DUST BOOTS
To prevent
oil from leoking through the
ioint
gop between the dust boot ond the joint
guord
os well os ony twisting of the boot during
the oction of the rood spring, or its domoge by
contoct with other cor ports,
it is importont to
observe its correct position
on the holf-oxle. lt
should be locoted
with its
flonges focing
reor-
wqrd ond tilted upword ot on ongle of obout
45o. For better occess, ploce
the clips fostening
the dust boot to the holf-oxle ond cover with
their screws on top. With the right-hond
boot,
screw in the clip screws from the front,
with
the left-hond boot the screw on the holf-oxle
from the reor ond on the cover from the front.
Connect the dust boot flonges with hollow
rivets using suitoble pliers.
lf riveting pliers
ore
not ovoiloble, bolt the flonges togethen instol-
ling odequotely dimensioned ploin
woshers
under the bolt heods ond nuts.
5.7 HALF.AXLE SHAFT
The thrust ring of the beoring (behind
the
shoft toper) is pressed
on the shoft. lf it is ne-
cessory to renew this ring, for exomple ofter
repeoted replocements
of the beoring (see
Chopter 5.1, porogrroph
4), press
it on so
thot
it is removed 76 to 78 mm from the edge
of the
toper behind the shoft
threod.
100

*
Fir
il
.-q
Fig.
6.1/4 -
Costor Angle
It is imperotive to set the
ongle with regord to
the direction of forword
trovel os indicoted
by the orrow
Fig.6.1/5-Preporing front oxle for the condition
of check lood by inserting
steel bors of 181 mm
in diometer ond obout
220 mm long
The most importont points
from the point
of
view of driving ore the
toe-in ond the comber
ongle, the odiustment of which is permitted
by
the oxle design.
Adiust first the comber
ond then the toe-in
since o chonged comber
offects the toe-in.
We refroin from describing in detoil ony
meosuring method in view
of the lorge number
of existing gouges.
Insteod,
we odvise you
to refer to
the procedures recommended
by the
monufocturers of the gouges.
The check lood con be formed by blocking the
wishbones with bors occording to
Fig. 6.1/5.
Press down the cor with the hond, insert
the
bors under the wishbones so
thot they
beor
ogoinst the oxle brocket, ond releose the cor
to
let the bors be clomped. lf
clomping of the
bors
does not toke ploce
(which con hoppen on on
older cor with weokened springs),
consider the
condition os if the bors were
clomped, i. e',
corresponding to the position of the
front oxle
ot check looding.
The words "ot
full lood" describe o vehicle
looded so thot the distonce of the rubber deod
stop from the bottom of the
lower wishbone
stop is 20 mm (see olso porogroph
18) ond the
comber ongle of the reor wheels is 1". Meosure
these volues on oll wheels (not
only one front
ond one reor wheel) ond distribute the
lood os
necessory.
Toe-in To odiust the toe-in, screw
the right-hond ond
left-hond steering rods
symmetricolly (o
chonge
up to 1 mm con be effected by
one rod) ot
check lood so thot the distonce between the
wheel rims (or
ocross them) behind the oxle
(A+o) is lorger by the toe-in volue (o)
thon the
distonce between the rims
in front of the oxle
(A). To verify steering symmetry (correct screw-
ing of steering rods during
toe-in odiusting),
check the wheel lock position ot the
20" lock
ongle of the neorside wheel -
for the respective
volues refer to Chopter 1.7.
Slocken the steering rod
nuts ond rotote the
steering rods using on
olligotor wrench (Fig.
6.1/6). In oddition to the correct inflotion
pressure
of the tyres, poy
ottention to
severol essentiol
points when checking the wheel
olignment:
o) Ploce thewheel in the stroight oheod trovel'
ling direction;
b) The
steering rod ond the trock rod
must
not
be stressed. The stress con be eliminoted by
letting the cor swing
up ond down in its
suspension under the pressure of
your
honds
(olternotely press down ond releose
the
wings)
c) Prepore the oxle os
shown in Fig.6.1/5;
d) lf
o speciol gouge with
o scole for wheel
lock ongle setting is ovoiloble, odiust
the cor'
rect length of steering rods in
occordonce with
the position
of wheels in
check lock positions.
You will find the respective volues
in Chopter
1.7 "Steering".
Set the lock ongle
of the wheel
on one
side to 20' (on
o turn-toble) ond screw
the steering
rod of the other wheel to odiust
104

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prl
tht
rer
oul MT
ott
rec
.a
Fig
Dis S
boll
6-1C
rubl
ovo
exomple
50,000 km ond
more, check the wheel
comber ond prepore
suitoble woshers for its
correction. 2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels. 3. Proceeding from
inside the luggoge boot,
remove covers protecting
the threods of the
shock-obsorber piston
rods ond screw off the
nuts. Retoin the piston
rod by holding its flot-
tened end.
b) Operotions inside the cor
4. Remove the steering wheel, the steering
column cowling, ond detoch the steering
shoft
from the body -
see Chopter 7.8.
c) Operotions from under the cor
5. Remove the bolt of the connection of the
steering shoftwith the steering box ond releose
the shoft sleeve from the connection by pull-
ing the steering geor
inside the cor.
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed. 7. Detoch the onti-roll bor brockets from
the
body ond disconnect the rubber broke hoses
from the front broke systems.
Before discon-
necting the hose, cleon thoroughly the hose
connector ond its surroundings to prevent
foreign motter from getting
into the broke
system. For the some reoson,
wrop the
hose
ends in o cleon rog. Toke
the some precoutions
with the disconnected broke piping.
8. Ploce o roll-o-cor
iock under the oxle ond
remove the bolts (two
on either side
of the tele-
scopic shock obsorber) fostening the oxle to
the body from obove. 9. Compress the telescopic shock obsorbers,
lower the
iock, ond
move it with the oxle from
under the cor.
6.3 REFITTING FRONT AXLE IN
CAR
1. To reinstoll the oxle in
the cor, reverse the
procedure of its removol, i.
e., begin with the
porogroph 9 ond proceed
to the porogroph
1.
Coot the rubber
cup with greose
ot the point
of its contoct with the steering shoft.
2. While reconnecting the broke hoses, ob-
serve the utmost cleonliness ond bleed the front
wheel brokes if no other ports
of the broke
system hos been dismontled. (lf
such o dis-
montling hos token ploce,
bleed the brokes of
oll wheels ofter hoving fully reclosed
the broke
circuit). 3. Turn the wheels in the stroight oheod di-
rection before connecting the steering shoft
with the steering box. Fit the steering wheel tentotively
ond odiust the direction indicotor
switch -
see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
into full lock positions
to moke sure thot the
lock ongle is correctly limited by the king pin
socket stops -
see Chopter 6.5, porogroph
36.
5. Adiust the toe-in -
see Chopter 6.1.
6.4 DISMANTLING
FRONT AXLE
No speciol instructions ore required for
dis-
montling mony of the subossemblies. Accord-
ingly, only the bosic dismontling procedure
will be
deolth with ond porticulors
will be men-
tioned only os fon
os they ore necessory for the
sequence of operotions ond the use of iigs.
Ports which con be dismontled witlrout re-
moving them from the cor ore the wheel hubs
and beorings, the broke mechonisms, steering
orms, shock obsorbers, ond the
onti-roll bor.
lf ony odditionol ports
hove to be dismontled,
remove the oxle from the cor ond dismontle it
on the stond.
Dismontling Wheel Hubs
ond Beorings
1. Dismontle the broke mechonism os per
Chopter 9.1 ond remove
the wheel hub
cop
using the MP 6-124 drog. When using the MP
6-136 pull-off
cortridge, the hub cop hos to be
prised off with o
tyre lever or o similor tool.
Now remove the costelloted nutwith its wosher
ond pull
out the hub,
ossisting the removol
with
light blows of o mollet, if necessory.
2. Toke out the inner port
of the outer beor-
ing, then the seoling ring, ond, f
inolly, the inner
port of the reor beoring (cone
with topered
rollers). Prise out the seoling ring using o
scrrewdriver. Proceed corefully olong the ring
circumference to ovoid distorting the ring which
Fig. 6.4/1 -
Removing Hub Cop Using
MP 6-124 Drog
106

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ml
se
thr it
5tr
bo
Pock with
greose
the plostic
dust cup ond
press it over the nut till it snops home in po-
sition on the lever.
Refitting Upper Wishbones 4. When refitting wishbones
which hove
been olreody used in the cor ond which ore
rother doubtful (for
exomple,
o distortion is
suspected os o result of o crosh), inspect them
corefully ond stroighten
them, if necessory.
5. Press rubber bushes into the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol
or soop
woter (suds).
Put the
bushes into the wishbone eyes with their lorger
diometer first ond push
them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with com-
pressed oir so thot it does no ossist the slipping
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122 driIt,
dip the drift in petrol
or soop woter, ond, forcing
it through the rubber
bush, press
the spocing
tube into the bush.
Before pressing
it in, turn the spocing tube so
thot the
ioint of the
pockoged
bush foces the
top side of the wishbone.
7. Threod the wishbone pin
through the eye,
slip on it the cup with its dished port
focing
the bush, two wishbone brockets with the lugs
pointing owoy from the wishbone, ond the other
Fig.6.5/2 -
Pressing Spocing Tube
into
Bush Using MP 6-122 Drift cup with
its dished port
tbword the
other rubber
bush, ond threod the pin
through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port
of the
pin. To slip them on, hold them with their un-
connected ends on the pin
ond press
down. Use
o screwdriver to move one of the circlips into
the groove
of the pin,
ond push
the pin
with the
circlip in position
into the brocket. Clomp the
other brocket with the wishbone eye
in o vice
to compress the rubber bush, ond slip on the
other circlip. 9. lnsert the rubber deod stop into the wish'
bone.
Fig. 6.5/3- Instolling Circlip into Pin Groove
10. Reinstoll the
two ossenrbled wishbones
on the oxle body. Fit o ploin
wosher under the
spring woshers of the lug bolts. Instoll, from
obove, one 'l
mm or one 3 mm open (horseshoe)
wosher or the previously
removed woshers on
the horizontcrl bolts between the brocket ond
the oxle body lug. First tighten the horizontol ond then the ver-
ticol bolts. Fit the
cups on the wishbone pin
ond screw
down both nuts.
Refitting Lower Wishbones
11. Inspect the wishbones os per porogroph 4.
lnsert rubber bushes in
the eyes of the wish-
bone fnom its inner side. Threod the wishbone
pin through the eye, slip
on it the cup os with
the upper wishbone, then two pin
holders with
the recesses ot the inner hole focing eoch
other, onother cup, ond complete the operotion
by threoding the wishbone pin
through the
other eye. 12. Slip circlips on the wishbone pin
ond
lock with them the wishbone brockets in po-
sition. Proceed in the some monner os with the
upper wishbone (porogroph 8).
110
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Fig.6.5/5
-
Pressing-in Beoring Cups Using
MP 6-130 Jig
Fig.6.5/5 -
Instolling Seoling Ring
Using
MP 6-131 Jig 23-
Fit the disk broke bock plote
on the
steering knuckle ond fosten it by bolting down
the broke brocket. Use spring woshers to lock
the bolts. Drive home the wheel hub
on the
steering knuckle with light tops ond use o tube
to top home the beoring cone.
24. Fit the greose-pocked
cone of the outer
beoring on the steering knuckie, locote
the
shim on the beoring, ond tighten the nut with
o torque of 1.5 kpnr (15
Nm) while rototing the
wheel hub.
25. Top
the wheel hub ond the broke disk
with o mollet ond rotote
the wheel hub to bed
in the beorings. Bock off the nut
through obout
-180o
ond retighten it with o torque of obout 5 Nm
(0.5 kpm) while rototing the hub. Then bock off
the nut to the neorest cotter pin
slot (ot
the
most through 30"), ond lock it in this position
by inserting the cotter pin.
26. Check whether the wheel hub rototes
freely br-rt without ony noticeoble
cleoronce in
the beorings, ond secure the nut with the cotter
pin.
Fittirrg Steering Knuckles ond Wheel Hub
into Wishbones
27. Hoving thus ossembled the wheel, instoll
ii into the lower
wishbone, fit
o shim between
tl-re wishbone reor eye ond the resilient bush in
the king pin socket,
threod in the eccentric pin,
cind screw down the nut without tightening it.
28. Press
the wheel ogoinst tlre
upper wish-
borre ond connect it with it
by topping home
the wishbone pin
from the reor side
of the
oxle,
i. e., from the side of the shorter port
of the
king pin
socket. Slip the MP 6-108 pilot
pin
on
the wishbone pin
threod to focilitote threoding
of the pin
through the hole in the wishbone.
Tighten slightly the connection with the costel-
loted nut.
DK ? 2r+
Fig. 6.517 -
MP 6--108 Pilot Pin for
Upper
Wishbone Pin lnstollotion
112

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35.
Using
o meosuring rod
on which the dis-
tonces con be morked with o line, meosure the
distonce between the gouge plotes
when tunned
forwords ond reorwords (the plotes
must be
opproximotely horizontol). By turning both
steering rods, odiust the rood wheels so
thot tlre
distonce between the plotes
behind the oxle is
3 mm lorger thon the distonce in front
of the
oxle, ond lock the steering rods in
this position
by meons of nuts.
Fig. 6.5/10 -
Meosuring Front Wheel Toe-in
36. Rotote
the steering screw to check the
correctness of the steering geor
reossembly.
With the wheels in the right-hond ond left-
hond lock position
when the steering knuckle
obuts ogoinst the boss on the king pir-r
socket,
both extreme positions
in the steering
box
must be resilient,
without ony hord impocts.
lf this is
not the cose ond there is o hord
impoct, correct the odiustment by shortening
one steering nod ond lengthening
the other one.
37. Hoving odiusted the comber ongle
ond the
toe-in, retighten
o) the nuts of the eccentric pins
ond lock them
with cotter pins
b) the nuts of the upper wishbones ond lock
them with cotter pins
c) the bolts of the upper wishbone brocket
d) the nuts of the upper wishbone pins
ond
lock them by tightening the thin nuts
e) the nuts of the lower wishbones ond lock
them by tightening the thin nuts
f ) the
nuts of the boll
ioint pins (boll pins).
For tightening torques see Chopter 1.8.
38. Recheck the wheel comber, remove the
gouge, ond screw down loosely nuts ond wosh-
ers on to the protruding
ends of the lower
wish-
bone pins
in the following order: thin nut, spring
wosher, two ploin
woshers, onother spring
wosher, ond o thin nut. Fitting
Anti-roll Bor
39. Slip rubber
bushes on the centre port
of
the onti-rroll bor (close
behind the oblique bend)
ond f it on them the holder. After
hoving
threoded the other rubber bushes
on the
ends
of the onti-roll bor, instoll it in the brockets
on
the lower
wishbones, ond lock it in position
by
clomping the rubber bush by onother holder.
Secure the bolt of the holder with o spring
wosher.
Reinstolling Shock Absorbers ond Completing
Front Axle Reossembly
40. Using the spring instoller releose
the rood
spring ond then remove the instoller. Fit the
shock obsorber holder to the shock obsorber
eye ond connect them with o bolt with o costel-
loted nut. Lock the nut
with o cotter pin.
Threod the shock obsorber through the lower
wishbone ond the coil spning ond fosten it
with
bolts ond spring woshers.
41. Fill the wheel hub cop with
the recom-
mended greose
cnd drive it home
in the hub.
The greose will penetrote
into the beoring ond
lubricote it. Use the
MP 6-125 drift to ovoid
domoging the cop.
42. Screw down o greose
nipple on the bot-
tom beoring of both
king pins
ond lubricote the
enti,re oxle with the recommended greose.
Fig. 6.5/11- Driving-on Wheel Hub Cop Using
MP 6-125 Drift
6.6 STEERING KNUCKLE The steering knuckle is o unit formed by the
swivel pin,
the broke bock plote
brocket ond
guord, speciol self-lubricoting bushes, ond the
spocing tube. The right-hond ond left-hond
steering knuckle
con be identified bythe greose
nipple or nipple hole which must foce forwords.
114