1980 SKODA 120 LS Workshop Manual

t8
6lf SOI-g dl1t ut
6ulroeg
1o 6urduo;C
-
e/t t'6tJ
86t xo
0l-C='V 'surlr.ls eq1 dn les puo 'poo;eld
o
qyan Ouuoaq oql
lll ol slqD
og ol so os surlrjs
aql ]o uolsuaulp
palolnclDo
eql ol y7
t4dot6
-o:od qns pa1;1cads
so (tuu g;)
uollcnper aq]
puo uur g0'0 ppv'ktt'V '6ll
ut ,,9,, uolsuaulp)
6ur:oeq lotluer€lltp eql
]o ep!s Jeqlo
oql ro,
sur!r{s }o sseulOrq}
pa:!nba:
eq} eu!rlralsp puo
'VZ ol 77 sqdo.r6o.rod u1
peql:csep
rauuDtu eq] ul
1;esg; 6ugroaq
JelloJ pe.redol
atll puD 'sulqs
aql
'6u;.roaq rellor peJedol
aqt Jol uo!sueu!p eqr
ernsDap '6tl
yOl-g du\l eql
puo ge>1so6
oql qltM
Jsloc gq]
elouol '6ulsnoq
aql JaAo
uJnf -gZ
'uog11sod u;
6ugroaq re1;o: pe:edDl
eql ploq
ol
lloq pauesool
aq1 AJ1q6rls
ua1q611 '6u;snoq
eql ol 6rt aq1 lgoq
puo '(1og
s1g 6uguasool .ra1;o) 6tl
zOt-s dW aqt
1l uo aco;d '6u1snoq
eql ul eloq e^tlcedsa.r slr
uo trr elooo; '6ur.roeq
eql peJnsoeu
6urnog .g7
'esn JalDl Jo, aptsD suj!qs aql
lnd puo
ezrs
]sallDlrts ]xeu eqt dn elDru 'uo!s
-uor,urp palDlnslDs eql uJort psu!Dlqo
eq
louuDJ
ssaulc!r{} pallnba.r
aq}
ll 'sezls
anllcedser roq}
lo uo!lDu!quoc
alqol!ns o Iq peu
trlJelep oq
plnoqs (a;qgssod
lssllotus eql) requnu
pernb
-al sql puo 'rutu
L puo
e'0 'L'0 '90'0
lo sessou
-Ic!qr u! slqol!o^D eJD srrJtqs eql 'sur!qs
qltM
u! -
pall!' eq o1 acods eql s!
6ug.roaq eql ssorco
peJnsoeu ,,rv,, uotsueulp
eql puo
zlt'v'61)
u! "v, uo!suaurp
eql ueeMleq esuaJelltp eql
'anlD^ e6o:ano pelDlncloc
eqt uor, 'e1o1d
eql lo ssaulo!rl]
eql ''e'!
'urru
0L
6ug1col1gns lq 6ur.roaq aql
lo uolsueu!p
lonlcD
eql euluJelep puo -
s6uunsoaul
lDrenes uoJl
peulDlqo ssnlD^ aq]
lo e6o:ano aql elolncloc
- Buuoaq eql puo
e1old eq1 ssoJcD
,,C,, uors
-ueu!p eql alnsoeu ol releuoJctuJ
o 3sn 'tz
'(seco.r 6ur:oaq eql ul A11ca.uoc
poq llltrrr srellor eq1) do1 uo sr
e1o;d aq1
loql
os 611 eql u.!nl 'urro
eql 6urualq6rg allq1111 'uro eql umop 6urrvralcs Aq
a1o1d eqt uo
l! alocol
puo 'a1o;d
6tl eqf uo 6u1:oaq .ra;;o.r pe.radDl
arll
acold'6rl SgL-g d6 eLl]
]o urrD aql Mercsun 'tZ
s6ugroag eq1 6u11111 puo
6ugrnsoe6;
'sulrqs puo 6ultoaq .re1;or
paladol sql qllM
Alalo.rncco ul pell!l
aq o] sor{
uo!sueu!p s!qI 'ls!p
aq] ssojcD ,,v,r uo!suouJlp
aqt ornsDeu puD '6t!
Ugl-S dN eql MDrpqltM
'(do1 uo Je^oc eql qlrrvr
6ursnoq eq1 urnl) epls
leeqM uMoJc
aLll uo Ja^oc eql e^oujeu 'zz
]nu lcol -
Z 's6!l
tOL-g dt4 -
L
su!qs puo
sDugloaq Jellol pa.radol
.to1
pelgnbe: ecods
+o uorlouturale6
-
ZIEV'6lJ
4
I 'uo!loJl
-sn1g; 6ulrrtollol eql u! ur*oqs s! uotlon]ts str.lf
'sur!qs 6u11snlpo puo
s6ul.roaq .re11o.r pa.radol
ro1 secods eqr
ll!l s6!!
tgL-g dn eqr
;o sa6uo;;
ro scs!p (1.rodo pecro,)
pauedo
aql puo
pelsn!
-pD st s.roe6
;eneq eq]
lo qsDHeoq
?S,ft"UT,"
slnu lcol eql 6u!uelq6lt Aq suorysod
anllcadser
r!eq] u! s6!!
t0L-g dN eql
1o sa6uol;
peuado
eql lcol '1coj.roc
s1 qspllcDq
eql
il '(laeqm
uMoJc eql
lo suorlsod
lDJaAas ur
Alqorelard)
qsDlloCIr{ aql
{c€qcar pr-ro 'srvrol
JDlncr!c si1 411n1
uado o1 6t! yOL-Sd141
reqlo eql
,o elpuDq oql
lo puo
eql etDlou 'g"y
:a1doq3 aas -
anlo^ potl
-lceds aql ol qsollcpq
eql asoercep 'epls
laaqM
uMorc eql uo 6t!
uor-s dw eql
lo alpuDq eqt
lo
pue eql 6uyu.rn1 Ag '.ro1oclpul
lDlp eq] uo
qsol
-loog o^!lcedse: aql
llo poaJ
[]uD Ja]loqo
q]eol
eql lllun laeqM uMoJc eql
sloloj ueqf 'J3Aoc
eql io e6pa eqt
puD
lnu uorurd
eq1
lsuroOo
paddold JeArJpMeJcs D qltm
uorurd eql utDleu
'r{}ool laeqM eq} o}
alq!
-ssod so ro;nclpuad.reci sp s! rolocrpul
lDlp eql
;o 1u1od eql
lDql os
laaqM uMoro eql
elolor
puo eloq-lqOls dot 6ugsnoq eLll
,o sloq
aqi uo
JolDclpu! lDtp r1ltM 6tl
tOf"SdW eql
llolsut '!Z
'ltor.ls uoru rd Jols
lorl
-uora,llp eql flu16oBus uortocrn,!q sll q1M
6ll
LOL-g dl
l 3q1
esn
laaq/vl urv1or3
eql alDlor oI
leeqr* u^ orc
aq1 6u;11er1rrs
el!qM uollourllse
Aq qsog>1coq
eq] ou!urale6
'r.{sollcoq.re6:o; o 6urprnold uolurd aq} uoJl
'\fi'4.L-
&!'-
Y Ji
,t
qsollc
s/v\orpqlln
sqdo.r6oro
-or eql s/
selpuDq t
-sod ;o1uc
d1;c eq1 rr
-lcadser e
ap;nD eq1
slnu aql 6
'(g'; reldo
6u;.rds pur
1o euo;d
I
os sJoqsol
lo seloq el
Aq ssaul(
6ulsnoq et
uo;ugd aql
-po o/vll l.l
'tllrp
to!-t
lno/vlojrll I
eql lo oslD
s! l! 'slol
eql lo aso
aarql jo su
JaAOC Oql
eq] otu!
l!:
-uerall!p or
'6ugsnoq ar
-relllP oqr

4.3-4.4
F
I
t
F
i
!
I
r
{.3-4.4
6. Remo
b) Crownwl Tools:
Settin
not le
1. Install
one of the
Glave Cylir
that the p
pendicular
2. Lock
between tl"
cover. 3. Using
back and
clearance I
teeth. This gauge, anc
wheel(see legible the
O.18mm bi
4. lnsuffi
wheel is tc
increase tl
from the nc
the equiva
This will p
increase th
Excess c
thickness
Selector Si
To worl
shims to n
(a) Bac
(b) Act
Refitting C Assembly
29. Instc
ond the rel it with nutr
-looded brc
To
(a) O.3i
(b) o.2r
lf
the shims
connot be set up exoctly to the
colculoted thickness, determine o thickness
which would result
in o prelood
due to on
overoll increose of 0.03 to 0.07 mnr of the di-
rnension of the shims.
27. Ploce the topered roller beoring on the
respective bore, bolt the other MP 5-107
iig on
the housing ond rotote
the centre bolt to press
the beoring into the housing os for os it will go.
Remove the iig, fit the shrunk-on
ring on the
stor pinion,
and lock the ring in position
using
o circlip. Lubricote the beoring with oil, f it the
respective shims on the beoring ond the gosket
on the cover, ond bolt down the cover.
Turn over the housing ond press-in
the other
beoring in the some monner (the press-fitting
iig is olreody in
position),
instoll the preporred
shims, ond bolt down the cover with its gosket.
28. Meosure how deep is tlre drive shoft
beoring below the level of tlre housing
surfoce
ond compensote the difference
with shims up
to o moximum protrrrsion
of 0. I mm -F0.05
rnnr.
Fig.4.3/4 -
Press-f itting of Differentiol Toperecl
Rollr:r Beorings
Using MP 5-107 Jig
Shims 0.1 nrm to 0.2 mm thick ore ovoiloble.
Fit the gosket
ond the ossembled cover on the
housing ond fosten it with nuts ond spring
woshers (for the cover refer
to Chopter 4.5).
Swing down the beoring
with the speedo-
meter drive geors
in the cover into engoge-
nrerrt with the pinion
drive geor
ond lock the
beoring in position
by tightening the nut of the
beoring clip.
Adjusting crownwheel Bearing
Alternative Method a) Crown Wheel Bearing Preload.
Tools Dial Test Gauge and Stand
MPs -
1OG lever Setting:
Preload O.Ob -
O.10 mm
1. Before assembling Transmission casing
remove outer crown wheel bearing races. Leave
the bearings on the
differential housing.
2. Assemble transmission. DO NOT carry out
operation 17
above.
3. Fit the outer races into casing pressing
into
place using coned cover. Do not forget to fit
gaskets. On the Selector Shaft side (side
B) of the
casing fit
approximately O.60 mm of shims
between the coned cover and outer races. Ensure
there is
backlash between crownwheel and
pinion, increase the
shim thickness if required.
4. Fit Dial test gauge
so that pointer
rests on
the differential as shown in fig. 4.3/1A.
5. Lift Crownwheel assembly to determine
clearance between bearings (a).
. . lf this exceeds
O.2O mm decrease the clearance to between O.O1
and 0.20 mm by f itting
shims to Non-selector side
of casing. (b)
. . . When the clearance is between
0.01 and0.20 mm take
a reading. Addtothis0.OS
to 0.10 mm. Make a shim pack
to this thickness
and fit to non-selector side (side
A) of transmission
casing. Check some
backlash still exists between
the Crownwheel and pinion.
Example 1st Dial reading 0.3O mm
0.20 mm
Shim fitted
on non-selector side.
2nd Dial reading 0.07mm
Shim pack
required between
0.07 +O.O5 =O.12mm
and0.O7mm *O.1Omm
= 0.17 mm
Shim sizes available.
0.08, O.14, O.2O and O.SOmm
Shim size selected O.14mm. This
will give
O.07mm preload
tension to crownwheel
beari ngs.
The Crownwheel should now
turn freely with
little drag. Fis.
4.3/1A
82

t8
6tf ZOI-g 6y1 6ursn eptne
bugroeg lnoMorrll qclnlC
6u1noua5 -LlV'V'6lJ
'uoLls qclnlc aql
MDlpq]!rl'r pun
repur;Ao osoalar pa^oLUar
oq] q
Uel eloq aq]
q6norql
UDLIs eql
lo dr;c,uc
1uo.r1
oql to pue
aql
lllt '(aurledrd
e:r1ua aq] paelq
ol sADq ol ]ou sD os
esoq aLl] tuoJl
;eputlr\c
aql lcauuocs!p lou op) raputlAc (anols
qc1nlc)
aql IDrvrD
i]!l puD
aulDue aql a^oue: 'asod.ind
slr.l] roJ 'Joc
aql uro:l
sursruDqoau aq1 6ulnorue.r
tnoq]lM pacoldel
aq uDc
loes Uoqs qclnlc
eqf
loes llDrlS qclnlC
6ugcoldeg
st/ stNVHclt l
NOISSItASNVUT 9NrlrNvl tSrC V'V
'Iurl raurqs
6ursrena.r aql a^oqo eloq epls eql olu! (sduo;
6u1s;ener qlrvr peddrnba
s1 JDc eLll JaqleqM uo
6utpuadep) Marcs 6n1d o ro qol!MS
dtuo; 6uls.ran
-ar eql
llDtsul 'eloq
apls eqg 6n1d ol leuBou o
]noqll/v Marcs D
puD 's1ou6oru
q]!M s/v\eJss esn
saloq urogoq
eql 6n1d o1 'doc
>1cau relp+ eq]
6ursn ursluDqceur
eql esolc 'pe:;nba.r
sV 'tt
':apu11Ic eql lo 6ur:ds elll rapun
Jonoc D 6urpesul iq r-us;uoqcau
oql olur ssacco
6urnrD 6uluedo eql asolc puo'.rapurlAc puD
Je^el esDoler eql uo sBuuds ylo-11nd
1r1 '.rapur;Ac
oq] otrul -re6ur; puD
lnu qllM por
aql
trasul 'Zt
'slnu eql Japun sJOQr-DM 6uuds
oslD Uasu! 's6u1.rds
oprseg 'slnu
ql!M y
uelsol
puD 'raloc
eq] io 6ugrds
eql puD
6urlcod ql1rvr
repu;1Ic esDala.! qclnlc
eql
ll uo
alocol 'lo)3Drq
Alquasso aql uoJI uJs!uDq3eu eql e^oureu 'Lt
'Je^el eql o1 uo 6u1.rds eql )oor]
puo 'spua
6u1.rds eq1 uedo '6u;roeq
aql puD
llaM
lro eLll
uoaMleq
6u1.rds aql
llDlsul 'a^aals
or..ll
1o rlel aql uo
11o dup 'r{rosseoau
1 'g't
raldoq3
ol 6ulp.rocco palqruassD
eneels aql uorlgsod
u! ]t, puD
eprn6 e^aats aql
l!o qlltlrr
rDeLuS '0t le>lrDrq
popDol-
-6u1rds eql Je^o sJaqsoM 6urLds pLto
slnu qllM
ll
uelsD, puo '1-roddns
eql uo Je^al asDalar aLll puD
sl1oq 6ursnoq aqtr uo
l-roddns aql
llDlsul '62
A;quessy
loulJ puo
e^aals
lnomor4l rlclnlo 6utp;1e5
Jolsuejl ol suilqs LuLuoe'o
=
9'I x
0z'0
ecualoj]lp LULUOZ = tuur$
t'O- 9e'0
ralsuerl ol st!rqs alelnclec 01
Lurugt'O qsellceq
lenlcv (q)
ururg l'O parrnber qsellceg
{e)
-:elntlJol 0urilrro;;o1 eql esn anour ol surtls
lo ssoulcrql
aleuirxordde aql
lno )Jorlt 01
'aprs rolcal0s
-uou oql ol eprs lolcelos eql uloll sseulc!tll
urqs Burnou lq palceroo
sr eouereelc ssacx3
'qsellseq aql asearcul
pue esec ssoJce
loaq/lAuMorc aql
qsnd
ll!/v1 s!t{I
'oprs rolcolas aqr uo ssaulcil.ll luele^rnba atll
aceld pue
6ursec oqllo oprs roloalas-uou aql uroJl
ssaulcrql urqs e^ourer ocueJealc aql osPolcul
o1 'uorurd
aql qtrm
tlsoul ut Aldaap
ool st
leeqm
-uMorc leql selecrpur acueleolc
luelcl#nsul 't
'qsel)ceq uLuS l'0
- tt'O uaaMlaq salnBrl
eql
asn ueqt agqr6e;
lou sl slqlll '(z
uarl L/8'v'6lJ 79 a6ed eas)leaqm
uMoJc oq] uo uaurlM se eq plnoqs pue 'a6ne6
letp aql ulorl
peor
aq uec
luouanotu srql 'ql00l
uorurd pup
looqrur u^ olc aql uaamlaq scuelealc
lo lunoure eql aurruJalap ol
tluol pue
lceq
leaq^^u^/\orc eql elelor
gOt -
gdt^ Uu'tlr"io,
6urureler uorurd eql pue
lnu uotutd aql uoemloq
Jo^al elqelrns e 6ursn Aq uorutd aql
IOol'Z
'qlool
laaqlr,rr oql
ol elqrssod se le;nctpuad
-led se sr rolecrpur
lerp or.ll
;o lutod aql
leql
os loaLl^/\u^/\orc eql oleloJ
uaql 'lapullA3
enel9
qslnlc aql oururelal tol pasn
spnls aql
lo ouo
uorolecrpur lerp qlr/'/r
l0l -9dt/\l
lool llelsul 'l
'rurug l'O -
t !'O osn a;qtBe;
1ou
+l 'leoq^^uMorJ
uo paUtcods
sV :s6ulgag
'uorutd lool ol Ja^el
90 t- 9d1 l
to t- gdt^
:slool
'qsellcPq uotutd ;aaqlrrunrrol3 (q
'eOneD lerO e^oruaU'g (q)
(e)
qllM
/
laeqM
enr6 11
urLuol 'ep!l
uaa^ l(
uorsstu
sseulc
90'0 s!
uoa^ l€
aprs lol
[0'0 u€
spaecx
au tuJJ0:
v L/t'n
uo slsej
'pelrnbe
pue lae
ornsul 's
sr!rqs ll
aql lo (8
lll ol
lol
olur 6urs
lno fulec
't
a^eal 's€
6ursec r
tt-et

Remove the clip of
the
clutch throwout beor-
ing guide,
insert the MP 3-102
iig into
the guide,
open its iows, ond withdrow the
guide.
After
hcving renewed the seol ring, drive home the
guide using the MP 3-103 drift. The droin hole
in the guide
must foce
downword.
The lotest desing of the extrocting
iig hos
the type dcsiqnotion MP 3-112. Screw the
iig
bolt into
the
iig nut
inserted into the mech-
onism through the hole cleored by the removol
of the clutch releose cylinder. Jerk the
iig to
drive the guide
out of the housing.
Dismontling the Power Pock
For complete dismontling of the power pock,
remove it from the cor -
see Chopter 4.-1,
"Rernovol of Power Pock from the Cor". Then
proceed os follows:
1. Remove the front cover ond the cover of
the pinion boll beoring, the clutch releose
mechonism, ond the clip of the guide
of the
clutch throwout sleeve, i. e., oll component
ports ottoched
to both holves of the housing.
2. Remove the connecting bolts of the flon-
ges. Force oport the f longes using o screwdriverr
inserted into the chombers of the flonge feet
(lugs). Lifting owoy oll component ports
one
by one is the usuol procedure
of dismontling.
Toking oport of lorger units (pinion,
etc.) is
described individuolly
in the following
chopters.
3. Press out the beoring cups which hove
remoined in the housing ofter its holves hove
been seporoted.
Use the MP 5-107
iig supported
by the MP 5-108
iig.
Fig.4.al2 -
Pressing Out the Cup of the Topered
Roller Beoring
Using MP 5-107 ond MP 5-108
Jigs
4.5 FRONT COVER
The front cover ossembly forms
o self-con-
toined unit fitted to the georbox.
For both the
reossembly ond dismontling ploce
it on o work
bench. Assembling
Front Cover
1. Slip the rubber seol ring on the speedo-
meter beoring ossembly (beoring
with geors)
ond push
corefully the beoring, preferobly
by
o steody rotory motion, into the cover
iust for
enough to be oble to instoll the key
without
domoging the seol ring by the shorp edge of
the keywoy. For the some reoson, chomfer the edge of the
beoring bore before
instolling the beoring in
o new cover.
2. Lock the beoring in the oxiol direction by
instolling the key
ond spring woshers, ond by
screwing down the nut.
Slip the clip on
the
protruding pcrt of the beoring ond lock it olso
in the oxiol direction with o bolt, spring
wosher,
ond nut. Do not
tighten the nuts fully.
3. Instoll the oiled geor
chonge lever in the
cover while pushing
it only os for os the groove
for the seol
ring.With the lever in this position,
insent the seol ring
in its groove
ond push
forther the lever through the ring. Slip the
dust
boot on the lever ond ottoch it to the cover
with o length
of locking wire.
4. Attoch the fostening (mounting)
lugs using
copscrews ond spring woshers. There
is o right-
-hond ond o left-hond lug, ond their slots must
be turned owov from the cover.
FK 1t't4
Fig.4.5l1- Front
Cove'r Assembly
Dismontling Front Cover
Lift owoy the speedometer
beoring ofter
hoving removed the sleeve
clomping bolt ond
the key (held
down by the nut). Then
withdrow
the geor
chonge lever by simply pulling
it out.
4.6 PINION WITH GEARS The pinion
with geors
forms o self-contoined
unit to be instolled in the georbox.
Use o work
bench ond o press
fon both its ossembly onddismor
wheel sure t
Only c
wheel
m itted
drive.
4.8.
Whe
olso tl
o new
one is
Assem 1.P
the pi
the or" thrust
toworc
3-104 p
ground
the be, must t
meosul
2.S
collor I
ring ir
the grr
The rir
3.5 to I
th ickes
ond pu
speed
3.H
it the '
selecte
toword
dismor (by tol
itinp
free to
Clon
MP 3.1
Note
inner b
toining
either r
-speed
ports.
4. Tr
groovir
pinion.
friction
groover
groove!
5. On
ond fit
the nex sizes 3
84

98
6u1.r aql ;o a6uoqc
puD
lD^oula: peloadal
o Iq
palsnlpo aq uDc
ll puo
r.uur
lO'0+L'0 ]o sllrurl
aouojelol u!ql!M eq plnoqs
ocuDrDalc s!ql
'roa6 eq1 ,o ecuDJDalc
lDrxD aq] eJnsDeur
{11ou11
puo 'g
qdo.rBorod qlllur
ecuD!;dtuoc ur pa!r]
puo
paulruJalap 6ur.r o qllrlt
uo!}!sod ur
11 >1co1 '.roe6
peeds-pu7 eql
llDlsut 'enool6
palltruo Ilsnolneld
eql olu! 7 qdo.r6o.rod
u1 peuo!]ueu
s6ug.r;o
a6uo.r aql
lo 6ur.r
pelcalas
Aglro.rlrq:o uD
]!J -g
'ep!sD l! lnd puo
6u1.r eql a^ouar
ueql 'ulrrt
Z0'0+0 lo eouorDelc
D qltM
anoolD
aql u! ltl o1 sDrl
ll 'sl!ru!l
aouDrelol o1 p:o6e-r
tlll/!{ lselc!91 aq1 asn ol
puD
ssol3 sseulctLll
auo ,o sEur.r
;olanas Arl
o] papueuruoceJ
s!
ll
.Zlg'n.6H o1 6u1p.roco 6u1.r eql
A.r1 'anoo.r6
eqt u! lr, lselqBrt aql aq
ll!rl,r qctqM
ssau13t qI
6u1g uorlcrrJ
lo uotlou!rureleC
-ZlS'V'6lJ
(op lltrvr l.roddns puo
e1old
1o
adrtl Auo 'alqDl!o^D
]ou Jl :srDc
001 opolg
1o)
pDeH lsnrql puD
atDld
tgL-t 661 6ursn
6ur.roag uoru!d
;eneg uo-6utsse.td
-
Llg'V'6lJ euo sql
asn puo
ruur gg't
puD
tg't '09.t
sezls
eq1 6uotuo
luo:; 6ur.r eql esooqC 'anoo.r6
lxeu eql
olu! sapls Llloq uo sanoo.r6 qllM
Du!J oql
}tl puD
6ur.r 1co; aql JoJ
anoo:6 6u;rvro11o1
aql
r!u,O .S
'(sep1s qtoq uo senool6
llo qilM
6u1: auo puo
apls euo uo sanoorD
uo qrtrt
JDI!ujrs or"rr1) pe}il1
eq o1 s6u;t uollct4
6urugoura: aql
llo o1 sar;ddo
eruDs eql .uorurd
eql u! anoorB eq]
lcn:lsqo lou saop
6u1noo.r6
eql lo 6op
aql
loql os Dur.r
aql urnl .t
'sUod
u!-unr Jo] op
ll!M llo 6u11ocr.rqn1 -.roe6
peads-
-]sL Meu o.ro'uoruld
Meu o':oa6 rvreu D Joqlte
6ursn ueqM (eprqdgnsrp
unuapql;or,u 6u1uro1
-uoc) alsod o1Ago61 eLll rlllrlt s.roe6
;o eJoq reuu!
eql elDc!rqnl ol PePueuu.tocer s!
ll :aloN
'(u61sep rvrau) e.rn1x!t
LLL-t dhl
ro ggl-t
dt/ eql
olu! uorurd
aql duolg
sr :oe' eqr
r'ql arns
ororu
or" ;;L?ll.::t;til
lcol ol (a:nl.redo
slt ur
Utrp o
qltrlrr
Eurddol Iq)
qclgd anoor6 o {q 6ur.r aq} ulng '6u1;luDulstp
6u1.rnp pe^oLuer
6ur.r p;o
eql ro .roaB aql spJDMol
sa,roo:6 l!o sll
rlll/\,
6u1l uotlclJl
pelceles
A;snolnard eql
lresu! rvro11 '.roa6
paeds-1s; eql
t!
uo d31s 'l!o
r{1M qsnq
eq} ps:oorus
6urnog .g
-lsL sLrl
;o Du11co1
ronlue^e ,o,
"0,.o'!i?"oo";i;
anoor6 eql u!
lll rq6l] D sr
qcrqM
euo
]se{crql
aql lcelas 'uur
L'0 {q
dn peddals
uru g'C
ol g.t
rlorl sassoulclql rnol u! pel;ddns
elo s6uu aq1
'Iypqolns s1; I.r1 ol qsnq
oql puo
enoo.r6 eql
1o e6pe eq]
uoeMtaq enoo.r6
llDqs eql ur
6uir
uo!lc!r+ eql
llolsu! puo
6ur.roeq aql proMol
rolloc
sl! qllM qsnq
:oa6 paads.ls1-
aq] uo dtts .z
i6ug:nsoau
,t,o, pasn
s!
lt aJuls peDotuop
eq Je^au
lsnul
uogugd eql
lo aco;
puno.r6
aql 'ecor
6uuoeq aq1
uo -
6ursse-rd ueqnn uolu;d
aql
,o aco;
punorO
aql lca1o.rd ot
poaq
trsnrql aLll
r{}lM a1o1d
96;.6
dn aql esn 'lxau
pelll, aq o1 sloa6 sql promol
'a 'l ']Joqs
uoguld oql ulor+ ionrro 6urr
1snlq1
relno sl! qllM
6ulrDaq eql
1o grod
relno eql
11 uo dr;s
puD
po
r{}!M
}l roeus .uolugd
eqi
uo a3Dr 6ugroeq Jallor Jeuu! eqi sseJd.!
uo!u!d 6u;lquassy
'uolloredo Isrou esnoc o1 gdo
sl auo
Meu D qlim
Dulqsau .roe6 plo
uV 'euo.Mau
o
qllM UDqs 3^trp
eql uo :oa6 6utqsau
aLll oslo
aco;da.r 'sroa6
aql ]o auos 6ulrvraueJ
uoq6
'8't
leldoq3 aas 6u11totu
IDO!Jaunu Jtaql
JoJ 'e^!Jp
lourl puD
xoqloaD euo olu! pel1,
aq o] pelllur
-red s1 Jaqtrtnu euos eql ql!rlrr
palJotu
leeqm
uMoro puo
uolugd aql ql!M
.rrod peqcloru
o A1u6
'6ugqsau lsaq aLll
puo
ostou
lsertrrol aql
oJns
-ue ol ,{lquasso e^r}cales Aq paqcloul
alo
leeqM
urvro:c aql puo
uorurd
lg^aq eqt '6ur;luoursrp puo
l1qur,
lJoM D as
peu!oluo.
'tno l! 6u
,v\DrPqllM
puD lloq
reUD 6u!
Alc
?t?,t )t{t
{
lsnu slol{
-]t{6!r o st
6u1sn s6n1
re^oc eql
]snp eql a
qsnd puo
'uo11gsod s
anoo;6 eq.
aql u! rs^
.^
'leqsonn 6t
oslo 1! Ic(
aq1 uo d;
Aq puo 's.
Aq uo;1cer
u1 6u1:oe<
aq1 1o e6p
1o a6pa
d
1noq11m Ir
.ro; 1sn! .re
{q ilqorel (s.roa6 q1;
-opaeds er

1-
in the
other groove.
Chose the ring olso with
regord to toleronces cvoiloble
in one closs of
the rings os mentioned in the previous
Pqro-
groph. Check the cleoronce of the geor with
the oid of o diol indicotor.
Then remove the geor
including the friction
ring in the second groove
of the shoft.
7. Ploce the lock of the 1st' ond 2nd'speed
synchron izing clutch on the bench with
its
teeth downword. lnstoll
springs in the clutch
core securing them with greose
ogoinst folling
out ond insert the clutclr core with the shorter
side of the inner heod on
top in the respective
geor. Locote bclls (dio. 1ir
in.) on the springs, com-
p,ress the springs with
the fingers or using
o suitoble rod, cnd fit
the complete core
itrto
the geor.
8. Hoving thus osembled the synchronizing
clutch lock, instoll the synchronizing ring
fronr
the opposite side of the geor.
Now threod the
lock on the oiled shoft
with the geor focing
owoy from the shoft.
9. Instoll in position the
previously selected
friction ring with its groove
focing owoy from
the shoft (toword
the geor)
ond insert the
synchronizing ring into the fitted lock of the
synchronizing clutch. Slip the oiled geor ond Fig.4.6la
-
Assembling 1st' ond 2nd-speed
Synchronizing Clutch -
lnstolling the Core
ond Pnessing in the Bolls
the previously
selected friction ring on
the
oiled shoft. 10. Slip on the 3rd -
speed geor
ond secure it
with on
orbitrorily chosen ring from the ronge
of friction rings in complionce with the poro-
groph 2. Meosure the oxiol cleoronce ond odiust
it to 0.1*0.07 mm by o repeoted exchonge of
the friction ring. Now remove the geor,
lubricote it,
slip it on
the oiled shoft ond lock it in position with the
ring with the oil groove
focing the geor.
11. Proceeding occording to porogroph 2,
insert on orbitrory friction ring into the lost
groove, slip on the 4th-speed geor
ond tighten
the pinion
nut over o pilot
collor replocing the
beoring (for
exomple of dimensions dio.
25.5/38x26 with edges of the inner
bore chom-
fered to 1x45o). Mork the side of
the pilot
col-
lor which will be
turned toword the
nut so thot
the side focing the geor
connot be domoged by
impression. Adiust the cleoronce of the geor
to 0.1+0.07 mm by o repeoted trying
on (ex-
chonge) of the friction rings. Then remove the
geor ond the ring from the shoft.
12. Assemble the 3rd- ond 4th-speed synchon-
izing clutch using the some method os when
hoving ossembled thot of the 1st ond 2nd
speed. lnsert the synchronizing ring
into the
clutch ond slip the clutch on the oiled shoft
with the short side of the lock first.
13. Instoll the selected friction
ring in the
locking position
into the groove with its
oil
groove focing owoy from the shoft. Push or top
home the key into the spline of the shoft so
thot it posses
through oll friction rings ond its
end is ot leost flush with the splined shoft end.
Fig.
4.6/3 -
Locking 1st-speed Geor in Position
(turning the ring with o drift) with the Pinion
Clompecl in MP 3-105 or MP 3111 Jig
86 Fig.
4.(

L8
rul"rut!xDru D ()1
ll pulJ6 ',6ulJDaq
lelloJ aql
,o
acDl Jeuut
eql e^oulej ol AlDSSoceu s!
ll Jl .Z
'sJDa6 aql uollrsod
ug 6ur1co; s6u1-r uottctJl aql
{11qDr1s 6u1u.rn1 puo
(tL qdo:Borod
aas) ie1 eq1
6u1r,ro.rpq11M reUD lloqs aqt
]lo ueql 6urddrgs
Aldurls iq penoruel
eq ol Apoe: puD posDelor
erD seqolnlc 6urzluo:qculs puo
sloe6
;;o *o[u,
-JDeq eql elouer o] lloq sl!
alDloJ puo
6ur.roeq
eql uo re11nd 801-t d6 aq]
l!J'lnu sl!
llo Marcs
puD (tig'V puo
979'y s6;3 u! uo!lDrlsnlr
slt
eas) 611
901-e dru oql u! uo1u1d
eql dLuDlC '!
A;quessos;O uo!u!d
'ruru g'0 ol
0 jo
esuDJoolc D e^Del ol
lnq euoq
A11n; roe6 eql ssa.rd ol
lou pepuetutuooor
s!
]l
'uo1u;d eql puD
ssa.rd eql ueeMleq
11 ezeenbs
ol lou sD
os A;1n1aroc
:oe6 oql uo-sseJd
'(urd uo-pessald qlrm
roa6) :oa6 a^lrp raleuopaeds
eql uo-6u!ssard
Aq uorurd aql
,o I;quasso
aql elalduoC 'gI
'lJDqs oql lo eur;ds
eqt olul aLuoq
loeu s1r do1
puD '(g'L
reldoq3
aas anbtol 6uruelqBrl s1r .ro;)
]nu eql uMop
MeJcs 'uo!]olo.r
oerl iol
s.roe6
11o )oeqC 'lrDLls
aql uor] Ionno
6urcDJ rolloc eql qllM
6u1.roaq
lloq eql uo sserd '-roe6
papo oq] uo d11s puo
'UDqs eql llo 'qclnlc
6ulzguo.rqcuAs eql
+o 1col
aql olul 6u1r 6urzluorqcuis lsDl eq]
lresul 'tl
'pelDltIcDl
oq lllM Aa>g
1on1co aql
]o 6utrrtl eq] snql
puD
sDug.r uorlcli] peurnl
Auo uBllo
lllM 1'eu11ds
aql olu! paqsnd
u€qnn '1u1od
D ql!/v
Aa>1 (1o1rd)
Arloq;gxno uD aIDt! ol pepueuuoceJ
st
1r 'Il1uanb
-oll euop arD sqol Ilquassoa.r
Jl :e
I o
N 6tf
lli-e dn ro
SgL-t cJtA u!
1rN uorurd 6urua1q6r1 -
g/g't '6!l
Llslnlc 6utztuolqcur{s peads-qlt
puD -pJe -
g 'rlc}nlc
6urzruo:qcu^s peads
-puZpuo-lsL-g':oe6peads-rl]t-y';oa6paads-prt-e '.roe6
peads-puZ-7'na} peads-1s1--;_
uorurd pelquassv
A;e1a;duo3 -
S/g't'6!J
I 'pue
lJ
sl! pul
os uD
do1 .ro
lto st!
eql u!
uDqs
eql o'
Puz p
ueqM
-uor.lcu
all] eA
-xe) u
.ioe6 e
Aq pa6
loLll ol
-lo3 10
-ruor.lc
'o!p i
aq1 6u
ue1q6g
lsDl el
'z qdr
eql ql!
uollc
1o e6u
lsnl po
-olod e
aEuo.r
l! gJncr
aql u(
eJoa
p30(

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