Manual gearbox of car Skoda Kodiaq 1

Manual transmission — maintenance
Checking the gearbox oil level Note: Necessary special devices, control and measuring instruments, as well as auxiliary means. Spanner (T30023 (3357)). 1. Remove the lower engine and gearbox protection (for more...

Adjusting the gear shift mechanism
Note: To achieve correct gearbox adjustment, the following conditions must be met: All parts of the gearbox control and gear shift mechanism must be in good working order. The switching mechanism should not stick. In...

Gearbox Assembly — precautions
Precautions when working with a car clutch 1. Use the recommended brake fluid to add to the clutch reservoir. 2. Do not reuse brake fluid drained from the hydraulic clutch system. 3. Do not allow brake fluid to come...

Gearbox assembly — removal and installation
Removal 1. Remove the engine trim panel assembly. 2. Remove the air filter housing assembly (for more details, see the corresponding section in the chapter " Intake and exhaust system "). 3. Remove the battery and...

Gearbox disassembly and assembly — disassembly
All-wheel drive 1. Unscrew the bolt securing the right shaft with flange (arrow 1) using a special tip (T10107A). Note: The right flange shaft remains in the bevel gearbox. 2. Unscrew the lower connecting bolts of the...

Gearbox disassembly and assembly — assembly
1. Install the reverse gear shift fork (4) on the fork rod (3) for engaging 5th and 6th gears in the assembly position as shown in the figure below. 2. Reinstall the drive shaft (1), 5th/6th gear driven shaft (2)...

Gearbox Housing Repair — cover removal
Pierce the rubber center of the cover with a screwdriver (B) and remove the cover by levering the screwdriver in the direction of the arrow, as shown in the figure below.

Gearbox housing repair — hammering the cover all the way in
Gearbox housing repair - hammering the cover all the way in

Gearbox housing repair — removing the shift control shaft locking handle
Remove the outer part of the handle in its original position. Insert the screwdriver (A) into the handle hole (B) as shown in the figure below. Using a lever motion, remove the inner part of the locking handle in the...

Gearbox Housing Repair — locking handle assembly position
The mark on the handle (arrow) should point towards the connection point of the clutch booster slave cylinder (1). The dimension (a) should be approximately 45°.

Gearbox housing repair — pressing in the locking handle (arrow) of the gear shift control shaft until the pin stops
Note: The locking handle must be in its original position during installation (unfixed) position.

Gearbox housing repair — removing the shift fork rod bushing
Note: After removing the bushing, check it for damage and replace it if necessary. A. Puller with internal grip of the part 14.5... 18.5 mm, (Kukko 21/2). V. Kontropora (Kukko 22/2)

Gearbox housing repair — driving the gearshift fork rod bushing until the tool stops
Driving the shift fork rod bushing until the tool stops

Gearbox housing repair — you are pressing the bushing out of the gearbox housing
Place the gearbox housing on pressure plates MP3-406 and MP3-407 in such a way as not to damage the centering bushings in the gearbox housing.

Gearbox housing repair — pushing out the bushing from an undisassembled gearbox using a guide pin (t30074)
First remove the lock screw and the gear shift control shaft. Turn the gearbox so that the bushing does not fall into the gearbox.

Gearbox Housing Repair — identifying locking bushings
A locking sleeve with a flange (arrow 1) or without a flange (arrow 2) can be installed. To select the appropriate parts, please apply.

Gearbox housing repair — driving in the locking sleeve until the tool stops
The gearbox housing is bolted to the clutch housing. A. hammering in the locking sleeve with collar, mandrel (T10169). B. hammering in a locking sleeve without a collar, mandrel (T10362).

Gearbox housing repair — removing the housing with a needle bearing for the reverse gear shaft from the gearbox housing
Note: The needle bearing housing will become unusable as a result of removal and must be replaced. A. Puller with internal grip of the part 23.5...30 mm, (Kukko 21/4); V. Counterpore (Kukko 22/2)

Gearbox housing repair — pressing the housing with the needle bearing (a) into the gearbox housing
When pressing, install the guide ring (A) of the reverse gear axle onto the housing with the needle bearing. Support the gearbox housing with a support cup (MRZ-4012) directly under the bearing support.

Gearbox housing repair — removing the gearshift control shaft bushing
While holding the lead screw of the assembly tool (T30100), turn the nut (B). A. Puller with internal grip of the part 14.5... 18.5 mm (Kukko 21/2)

Gearbox housing repair — hammering in the plug
Tap the plug (1) with a pressing mandrel (T30033) in such a way as to maintain dimension (a) = 3 mm under the upper edge of the gearbox housing.

Disassembly and assembly of the drive shaft — disassembly
Removal a radial ball bearing 1. Remove the retaining ring from the drive shaft. 2. Install the clamping device (MP3-453 (VW431)) and the clamping plate (MP3-467 (40-105)) on the drive shaft, as shown in the figure...

Disassembling and assembling the drive shaft — removing the roller bearing from the clutch housing
When removing, squeeze the roller bearing retaining ring (arrow) with pliers (C) as shown in the figure below. A. Kontropora (Kukko 22/2).; B. Puller with internal grip of 30...37 mm (Kukko 21/5)

Disassembling and assembling the drive shaft — pressing the roller bearing into the clutch housing
When pressing in, compress the retaining ring (arrow) of the roller bearing with special pliers (A), as shown in the figure below. Before the bearing is installed in the required position, it is necessary to remove the...

Disassembling and assembling the driven shaft (from 1st to 4th gear) — removing the disc (a) from the driven shaft
Removal the disc plate (A) from the driven shaft

Pressing a disc into a driven shaft
Pressing a disc into a driven shaft Press the disc into the driven shaft up to dimension (a)-. Size (a) = 2 mm + 0.5 mm. Note: The disc plate should be pressed in a maximum of 3 mm, not deeper.

Removal the outer race of a tapered roller bearing
Removal the outer race of a tapered roller bearing A. Kontropora (Kukko 22/2).; B. Puller gripping the part from the inside 56... 70 mm

Pressing the outer race of a tapered roller bearing into the clutch housing
Pressing the outer race of a tapered roller bearing into the clutch housing Support the clutch housing with a support cup (MP3-450 (VW 415A)) directly under the bearing support bracket.

Pressing out the inner ring of a tapered roller bearing
Pressing out the inner ring of a tapered roller bearing Remove the retaining ring. Install the mandrel (MP3-453) into the driven shaft and place the washer (MP3-467) on it, as shown in the figure below.

Removal the sliding clutch and synchronizer carriage for 3rd and 4th gears with the 4th gear pinion
Removal the sliding clutch and synchronizer carriage for 3rd and 4th gears with the 4th gear pinion Remove the retaining ring. Note: If necessary, heat the 3rd and 4th gear synchronizer carriage with a hot air gun....

Separation of the sliding clutch and synchronizer carriage for 1st and 2nd gears
Separation of the sliding clutch and synchronizer carriage for 1st and 2nd gears After removing the retaining ring, press out the 2nd gear, sliding sleeve and synchronizer carriage together.

Pressing out the inner ring of a tapered roller bearing
Pressing out the inner ring of a tapered roller bearing A. Split puller 22... 115 mm

Pressing in the inner ring of a tapered roller bearing
Pressing in the inner ring of a tapered roller bearing

Inner ring wear check for 1st, 2nd and 3rd gears
Inner ring wear check for 1st, 2nd and 3rd gears After pressing the inner ring onto the cone of the driven gear, measure the size (a) with a feeler gauge. Size "a" Admission of new parts Wear limit 1st, 2nd and 3rd...

Checking the wear of the synchronizer locking rings for 1st, 2nd and 3rd gears
Checking the wear of the synchronizer locking rings for 1st, 2nd and 3rd gears Install the synchronizer locking ring, outer race (ring) and inner ring on the cone of the driven gear, measure the size (a) with a feeler...

Disassembly and assembly of the sliding clutch and synchronizer carriage for 1st, 2nd, 3rd and 4th gears
Install the sliding sleeve through the synchronizer carriage in the assembly position. The grooves for the synchronizer locks on the synchronizer carriage and on the sliding sleeve must correspond to each other. 1....

Position for assembling the sliding sleeve and the synchronizer carriage for 1st and 2nd gears
The chamfer on the sliding sleeve (arrow 1), if there is a chamfer, and the narrow flange (arrow 2) of the synchronizer carriage are directed towards 1st gear.

Pressing in the sliding sleeve and the synchronizer carriage for 1st and 2nd gears
Install the retaining ring.

Position for assembling the outer ring for 1st and 3rd gear
The projections (arrows) point towards the synchronizer carriage/sliding clutch (A).

Position for assembling the synchronizer locking ring (inner ring for 1st and 3rd gears)
The projections (arrows 1) enter a fixed position in the recess (arrows 2) of the synchronizer locking ring (B).

Driven gear assembly position for 1st and 3rd gears
The taller flange (A) faces 2nd and 4th gears (B). The grooves in the flange (arrows) fit into the projections of the outer race (ring).

Position for assembling the sliding sleeve and the synchronizer carriage for 3rd and 4th gears
The shoulder (arrow A) on the sliding sleeve and the wider flange of the synchronizer carriage (arrow B) are directed towards 3rd gear.

Pressing in the synchronizer carriage with a sliding clutch for 3rd and 4th gears
Install the retaining ring.

Checking the wear of the synchronizer locking ring for 4th gear
Install the synchronizer locking ring on the driven gear cone and measure the dimension (a) with a feeler gauge. Size "a" Admission of new parts Wear limit 4th gear 1.0...1.7 mm 0.5 mm

Pressing in the inner ring of a tapered roller bearing
Having determined the thickness of the retaining ring, install it. Determining the thickness of the retaining ring Determine and install a retaining ring of the greatest possible thickness that can be used. The...

The outer ring (cage) of the tapered roller bearing has been removed from the gearbox housing
The outer ring (cage) of the tapered roller bearing has been removed from the gearbox housing A. Counterpoise.; B. Puller with internal grip of the part 46...58 mm

Pressing the outer ring of a tapered roller bearing into the gearbox housing
Place an adjusting shim under the outer bearing race. Support the gearbox housing with the pressure piece (T30042) under the bearing support.

Monitoring wear of the inner friction surface of the outer ring
First install the inner ring (1) on the driven wheel, and then the outer ring (2), as shown in the figure below. Press the outer ring onto the cone of the inner ring and measure the gap (a) in 3 places, mutually offset...

Control of wear of the outer friction surface of the outer ring
Check and ensure that there are no scratches or signs of radial wear on the inner friction surface of the synchronizer locking ring (arrow); otherwise, replace. The inner ring, outer ring and synchronizer locking ring...

Position for assembling 3rd gear synchronizers
Install the inner ring (B) onto the driven gear (A). Install the outer race (C). The projections (1) of the outer race (C) must enter the recess (2) of the driven gear (A). Install the synchronizer locking ring (D). The...

Inspection of the inner friction surface of the outer ring for wear
The inner ring (1) and then the outer ring (2) should be inserted into the assembly positions on the driven wheel, as shown in the figure below. Press the outer ring onto the cone of the inner ring and measure the gap...

Checking the outer friction surface of the outer ring for wear
Check that there are no scratches or signs of radial wear on the inner friction surface of the synchronizer locking ring (arrow); otherwise, replace it. The inner ring, outer ring and synchronizer locking ring should be...

Checking the wear of the synchronizer locking ring for 4th gear
Install the synchronizer locking ring on the driven gear cone and measure the dimension (a) with a feeler gauge. (A) Brass synchronizer Gap size (a) Installation size Wear limit 4. speed stage (transmission) 1.0...1.7...

Disassembly and assembly of the driven shaft (5th and 6th gears) — removal of the outer race of the tapered roller bearing
Note: After removing the washer, check it for damage and replace it if necessary. A. Kontropora; B. Puller with grip of the part from the inside 46... 58 mm

Disassembly and assembly of the driven shaft (5th and 6th gears) — pressing the outer race of the tapered roller bearing into the clutch housing
Place a gasket under the outer ring. Support the clutch housing with a mandrel (T30091) directly under the bearing support.

Removal the inner ring of a tapered roller bearing
Remove the retaining ring. Before installing the puller, it is necessary to install a mandrel (MRZ-453) and a washer (MRZ-467) on the driven shaft.

Pressing out the sliding clutch and synchronizer carriage for 5th and 6th gears with the 6th gear driven gear
Remove the retaining ring.

Pressing out the sleeve with the driven gear of the reverse gear
Remove the retaining ring first.

Pressing out the synchronizer carriage for reverse gear
Remove the retaining ring. A. Split puller 22... 115 mm

Removal the inner ring of a tapered roller bearing
Before installing the puller, install the pressure plate (MRZ-410) on the driven shaft.

Position for assembling the synchronizer carriage for reverse gear
The limiter (arrow A) for the reverse gear sliding clutch is directed towards the teeth of the driven shaft (arrow B).

Pressing in the synchronizer carriage for reverse gear
Install the retaining ring.

Pressing in the bushing
Assembly position: wide flange facing reverse driven gear.

Checking the wear of the 5th and 6th gear synchronizer locking ring
Install the synchronizer locking ring on the driven gear cone and measure the dimension (a) with a feeler gauge. Size "a" Admission of new parts Wear limit 5th and 6th gears 1.0...1.7 mm 0.5 mm

Disassembly and assembly of the sliding clutch and synchronizer carriage for 5th and 6th gears
Place the sliding sleeve over the synchronizer carriage. The grooves for the synchronizer locks on the synchronizer carriage and on the sliding sleeve must correspond to each other. 1. Spring; 2. Fixators; 3. Sliding...

Assembling the sliding clutch and synchronizer carriage for 5th and 6th gears
The sliding clutch is installed on the synchronizer carriage. Install the synchronizer retainers and mount the springs, offset by 120*. The beveled end of the spring should enter the hollow synchronizer retainer.

Pressing in the sliding sleeve and the synchronizer carriage for 5th and 6th gears
Install the retaining ring.

Pressing in the inner ring of a tapered roller bearing
Determine the thickness of the retaining ring, then install it. Determining the thickness of the retaining ring Determine and install a retaining ring of the greatest possible thickness that can be used. The following...

Pressing in the inner ring of a tapered roller bearing
Pressing in the inner ring of a tapered roller bearing

Removal the outer ring (cage) of a tapered roller bearing from the gearbox housing
Removal the outer ring (cage) of a tapered roller bearing from the gearbox housing A. Kontropora; B. Puller with grip of the part from the inside 46... 58 mm

Pressing the outer ring of a tapered roller bearing into the gearbox housing
Support the gearbox housing with the support (T30042) under the bearing support.

Checking the technical condition of gearbox components in case of its disassembly
1. Inspect the thrust surfaces on both sides of the gears for the following defects: Wear. Surface abrasion. Bullies. 2. Gears with damaged bearing surfaces must be replaced. If this defect occurs, the gears may...

Cleaning and inspection of bearings and spacers
Note: Do not allow the bearing to spin freely; rotate it slowly by hand. Failure to do so may result in damage to the bearing race and rollers. 1. Mark the original order and orientation of the bearings. 2. Clean...

Cleaning and inspection of synchronizers
1. Clean the synchronizer parts in solvent and dry them with air. 2. Ensure that the synchronizer hubs have a tight fit on the corresponding shaft. 3. Synchronizer hubs that do not have tension when fitted onto the...

Manual transmission troubleshooting chart
State Possible reasons Action Clutch slippage Clutch master cylinder Clutch slave cylinder Clutch pressure plate Clutch driven disc Leaks of oil or working fluid from the engine or gearbox housing in the block with the...

Final drive assembly with differential — repair
Pressing out the outer race of the tapered roller bearing from the clutch housing Remove the shaft sealing ring (oil seal) bushing with flange as shown in the figure below.

Pressing the outer race of a tapered roller bearing into the clutch housing
There is no adjusting shim on the clutch housing side.

Removal the inner rings of a tapered roller bearing
Before installing the puller, install the pressure plate (MRZ-467 (40-105)) on the differential housing. Note: The removal of both inner races of the differential case tapered roller bearing is the same.

Pressing in the inner rings of a tapered roller bearing
Note: The inner races of the tapered roller bearings of the gearbox housing and the clutch housing are installed using the same tools.

Pressing the outer ring of a tapered roller bearing into the gearbox housing
Place an adjusting shim under the outer bearing race. Support the gearbox housing with a bushing (MRZ-474 (3144)) directly under the hole for the bearing. Distinguishing between spring loaded pins Size "a" mm...

Removal and installation a short pin with a spring (with a groove around the perimeter) of the satellite axle
Removal 1. Cover the inner ring of the tapered roller bearing to prevent possible damage and metal chips. 2. Knock out the elastic pin with a chisel; install the chisel into the perimeter groove. Installation 1. Press...

Removal the long pin with a spring (without a groove around the perimeter) and pressing out the satellite pin
Note: When pressing out, the elastic pin is cut off with scissors. The remaining portion of the elastic pin must be knocked out of the differential housing.

Installing a long pin with a spring (without a groove around the perimeter)
Align the hole in the satellite axle with the hole in the differential housing. Hammer in the new pin and spring to dimension "a" = 3.0 mm. Be careful not to allow the pin and spring to come into contact with the...

Installation of axle gears and bevel pinions of the differential
Install the spherical bearing, pre-lubricated with transmission oil. Install both axle gears and secure them(eg shaft with flange). Install both bevel gears of the differential, mutually offset by 180'. Drive the...

Assembly position of the friction ring for the conical ring
The flange (arrow) is directed towards the spring (B). Some gearboxes have projections (A). The projections (A) are directed towards the conical ring (1).

Differential adjustment
1. Press the outer ring (cage) of the tapered roller bearing into the clutch housing using a special mandrel (MPZ-464 (30-205)). Note: The inner ring and outer race of a tapered roller bearing are matched. Don't get...

Diagnostics and checks — inspection and testing
1. Ensure that the customer's complaint is justified. 2. Perform a visual inspection for obvious signs of mechanical damage. Oil leaks. Visibly damaged or worn parts. Loose or missing nuts and bolts. 3. If an obvious...

Diagnostics and testing — final drive axle
Malfunction Cause Solution Presence of extraneous noise (when starting off) Oil leak Topping up Low viscosity oil Replacement Oil clogging Replacement Increased clearance of the main gear pair Adjustment Wear or damage...

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Kodiaq 1 (2016-2024)