1980 SKODA 120 LS ECU

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.(

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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

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