1980 SKODA 120 LSE oil

4.3-4.4
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{.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

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

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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eil
ell
€; \l-
I
4.9-4.
r
O
Fig. I
((
,'.ffi
l|i
3. To evoluote
the doto
obtoined from
the diol
indicotor reoding ond the
doto of the geor
set,
odopt the following procedure:
The setting distonce of the gouge -
60.00 mm
- is morked on the gouge
orm; the reoding
of
the diol indicotor
hos shown
o deviotion
of e. g.
plus 66 divisions, i. e. 0.66 millimetres (plus
meons thot the tip
of the gouge is pushed
in-
word from the set zero position
ond the in-
dicotor reoding is higher;
o reverse deviotion -
minus reoding -
connot procticolly
occur). By
subtrocting this deviotion from the meosure on
the gouge, the octuol distonce between the
pinion ground foce ond the geor
cross oxis will
be obtoined,
i. e. 60.00 mm minus 0.66 mm :
59.34 mm.
The meosure on the crown
wheel indicoting
the ossembly
distonce of the pinion
is, foi
exomple, 59.60. Accordingly,
the pinion
must be
moved slightly
out of the housing
0.26 mm, i.
e.,
by the difference
of the two
meosurings (59.60
minus 59.34:0.26 mm).
4. Prepore
odiusting
sirims 0.30 mm thick to
be inserted
under the flonge
of the pinion
beor-
ing on further
ossembly of the housing.
Shims 0.14, O.2, 0.3, ond 0.5 mm thick ore
ovoiloble. lf the required
occurote outword shift-
ing of the pinion
connot be ochieved
with shims
of ony of the specif
ied thickness, combine them
to obtoin
the next higher
volue.
Note: The thickness of shims required
for the od-
iustment of the
pinion
con be olso
colculoted
in the following
woy:
o) Set the diol indicotor
of the Mp 5-103 gouge
os in porogroph
1of the preceding
texi i.6.,
with the gouge
odiusted on the meosuring
contoct, the reoding
of the diol indicoto-r
will be 1.00 mm.
b) .Swing the
tip of the diol
indicotor
ogoinst
the pinion ground foce ond push
the
iinion
by meons
of the Mp 5-102
beorinq
retoiner
into the housing
till the diol
indicitor reods
1.00 mm. pointer
ofter pushing
the pinion
into the
housing is the meosure (thickness)
of the
shims.
4.9 DIFFERENTIAL
Assembly 1. Instoll the sun geor (plonet)
without the
friction wosher, the two stor pinions
(sotellites),
ond the pilot pin
for the stor pinions
into the
left-hond holf of the differentiol cose (with
the
flonge for the crown wheel). The originol
dif-
ferentiol pinion
shoft pressed into the cose
must be reploced tempororily by the pilot
pin
to focilitote hondling. 2. Push the sun geor
from outside into
en-
gogement with the stor pinion
teeth ond
use
o depth gouge
to meosure the dimension by
which it protrudes
from the housing. Then, pro-
ceeding from inside, push
the sun geor
into the
obutment surfoce of the differentiol cose ond
meosure ogoin
by how
much lt protrudes
from
the housing. The difference of both meosure-
ments determines the gop
for the sliding ring.
The rings ore supplied
in thlcknesses of 1.8,
1.9,
2, 2.1,2.2, ond 2.3
mm. Select the ring whlch is
0.1 mm thinner thon
the colculoted dimension
of the gop.
Fig. 4.9/1- Sectionol View of Differentiol
The orrow points to the mork indicoting the
side for pressing-on
the differentiol pinion
shoft. Any symbol con be used (o
figure, o let-
ter) but it must be identicol for both ports
of
the differentiol. lt olso indicotes the
correct
relotive position of the two differentiol ports.
c)
d) Push,
the pin-ion further into the housing
{while w.otching
the deflection
of the poin-.
ter) until the ossembly
meosuring
is ob-
toined (the 59.60 meosure
on th; crown
wheel) , i.
e., by the dif ference
of this
meosuring from 60.00
mm -
in our exomple
60.00 minus 59.60:0.40
mm.
Without chonging the position
of the
diol
Indicotor, push
the pinion into the housing
gs for os
it
will go -
the difference
of th6
d.iol reoding
from the previous
0.40 mm is
the thickness
of the required
shims (0.26
mm). Or, without chonging
the position
of
the diol indicotor on tfrJ pinion,
trin tf,e
scole to zero (0).
The
deilection
of the
90 Fig-

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5.
rl in
t-o o
el
st
th
w
ce
re
q
tr
t
Fig.
5.1i3 -
Forcing Slroft out of Beoring Using
MP 5-113 Jigs ond Jirrs os per
Fig. 5."1/1
The oxle shoft moy Inove out of the holf-oxle
only to such on extent thot the reor edge of the
beoring thrust ring is flush
with the holf-oxle
socket. Otherrwise it is opt to
foll out of the
epicyclic geor
ond its refitting would require
the removol
of the holf-oxle from
the georbox
housing. 4. To fit o new boll beoring proceed
occording
to Chopte'r 5.2.
Pull out ogoin
the shoft slightly
until the thrust ring con be seen, fit the beoring
I I
I of the
broke mechonism
odhering to the in-
structions of the obove-mentioned chopter,
lo'
cote the beoring
shim 0.3 mm thick, ond com'
plete the ossembly.
Note: The 3 mm shim should
be used only
when replocing the wheel hub or when elimirr-
oting on oscertoined shoft ploy,
thot is
to soy
if the shoft moves oxiolly ond
knocks. However,
it is recommended never
to use more shims
thon three.
5. A domoged seoling
ring con be removed
with o hook or o needle, ond o new one driven
or pressed-on.
The lotter olternotive should be
preferred with regord to the visuol checking of
the pressing-on operotion. The
tightening fin
ond spring of the pocking
hove to be
tunned in-
side the holf-oxle.
When driving home the seol
ring, slip the
MP 5-114 pilot toper (see
Fig.5.213) on the
shoft,
smeor it with oil, ond move the seoling
ring
olong it to drive it finolly into the holf-oxle
using tlre MP 5-116 drift os shown in Fig-
5-212.
For pressing-on
the seoling ring, use the MP
5-112 iig (see
Fig. 5.214)
ond the, sleeve
with
toper os per
Fig.5.-1l4. Pull the shoft
slightly out
of'the holf-oxle, slip
on it the oiled toper os
shown in the illustrotion, then the
seoling ring
ond finolly the sleeve. Fosten the MP 5-112
iig
screwing its heod on
the holf-oxle threod, slip-
the seoling ring on
the thrust ring
by meons of
the sleeve, ond turn the wrench to
press
the
seoling ring into the holf-oxle.
Now the beoring con
be pressed ott.
l^5
oi ro --
€D
.90 DK 827
4 '%
I i5
t"'
I
-l
b
F)
g
d
e \
r
e
.l I
€['----
Fig. 5.1i4 -
Sleeve ond Toper for Pressing'on
Holft-Axle Seoling Ring (toper
surfoce
smoothed out during monufocture)
12
90
6"44 t;)
20 96

5.:
pr
stl
bc
5-t
bo
thr
u*,
on
dit
on arI
ioi
sPl
SW
I
gor
:
wo
bol
cyl
del
\
mo
th€ hot
WO
F
clo
POS +:
nec
wol
reo
toe
wit
T
o)
b)
Alil 1.
con
sloc
seo'
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).
il
i
ii
I
I
I
I
lr
il
H, DK
?EI
98