ECU SKODA 105S 1980 Owner's Manual
[x] Cancel search | Manufacturer: SKODA, Model Year: 1980, Model line: 105S, Model: SKODA 105S 1980Pages: 238, PDF Size: 47.09 MB
Page 78 of 238
r
t
i
5. Prc
scri bed
rods onc
4th spee
fork rod,
irr the b
6. lnsl
guide bu
cover inr heods. S
tob wos
edges of
F it thr
stri ki ng
weoker s
ing forks 7. Tigl
the forks fork rod
the strik
function
Reverse-:
Fig
-1 - Rever
2-1st-o
3-3rd- o
4 -
Rever
8. Inst
press-f ittr
verse-spe
inside th
through t
Turn tl'
end foces
lock it in
hole. Tigl
Pinion Ar
9. Instc
ing ond,
r
_-_-- -
. i\:r,,,
\. 43
Fig. A.1l'l -
Power Pock
1 -
engine with mounting, 2 -
georbox/f inol
drive with
mounting, 3 -
reor oxle (holf-oxles),
4 -
rodius orms
retighten it using the recommended torque
(Chopter 1.8) ond screw down the clinch nut.
lf necessory, top up engine oil, f ill the cooling
system witlr on qntifreeze,
bleed the broke sys-
tem, ond
odiust the hond broke.
For the fosten-
ing of broke hoses (routing)
see Chopter 9.7.
4.2 ASSEMBLING
GEARBOX
Generolly, the reossembly
p'rocedure
depends
on the extent, to wlrich the unit hos been token
oport. For betterunderstonding,
we sholl des-
cribe the procedure
ond peculieorities
of reos-
sembly of o completely
disossembled unit.
Gear Chonge Mechonism
. 1.
Clomp the right-hond holf of the housing
(when viewed from the flonge securing
it to
the engine) in the MP 9-101 stond
com-
plemented with the MP 3-101 georbox
rock, ond
check the housing for completeness.
2. Instoll
circlips on the striking fork rods
of
the reverse
ond 1st ond 2nd speed. The ring
with the lower
nose is to be fitted
on the 1st--
ond 2nd-speed rods.
3. lnsert the reverse speed
striking fork rod
into the housing
so thot the inserted
end pro-
trudes slightly from its guide,
slip on it the
striking fork with the longer
side of its heod
first,- ond push
the striking fork rod through
the fork
ond the end of the guide
os for os=it
will go. 4. Fit tlre
MP 3-109 jig
into the free holes for
striking fork rods (both pins
of the
iig), ond
proceeding through the hole in its side ond
using o stick or o length of wire, push
the lock
pin into the housing
os for os it will go.
Proceed
in the some monner for
inserting the next pin
(use one pirr
of the
iig). Shift
it
iust so thot
the centre lrole remoins free for inserting
the
striking rod.
Puslr the lock pin
into the end
guide of the strikirrg
fork rods olso os for os it
will go. The
iig is not required
for
the instol-
lqtion of this pin.
Fig.4.2l1- Clomping Georbox Housing in Stond
Using MP 3-101 Rock
Fig.4.212 -
Locking Striking Fork Rods in
Position bv Meons of Lock
Pins ond Bolls
78 Fig.4.2l3
-
Instolling Lock Pins Using
MP 3-109 Jig
Page 80 of 238
Proceed
in the some woy with the
3rd- ond
4th-speed geors.
lf the morked position
of the neutrol is not
midwoy between the side morks (check
visu-
olly), remove the pinion,
mork the positions
of
the striking forks on
their rods (preferobly
on
either side), slocken the forks ond 'rnove
them
toword the required centre by
the distonce of
the deviotion of the neutrol morking. Then lock
the striking forks in position
with screws.
For the striking fork tightening torgue see
Chopter 1.8. 13. Adiust the reverse geor position
so thot
there is o gop
of obout 2
mm between its teeth
ond the odioining teeth, ond swing the striking
fork of the first ond second speed
to moke sure
thot it connot foul
the teeth.
14. Reinstoll the pinion
with its respective
woshers ond lock it in position.
Shift the strik-
ing fork rods to moke sure thot, for exomple,
o movement opposite to the required one of the
striking forks did not toke ploce,
i. e. thot the
neutrol is midwoy betvr'een the engogement
positions of the synchronizing clutches. Correct
ony error ond remove
ogoin the pinion.
Fitting Drive Geors ond Clutch Shqft
15. lnstoll the ossembled drive shoft into the
housing ond slip the splined bush on it.
Top home the seol ring with its seoling lip
pointing outwords into the guide
of the clutch
thrrowout sleeve, ond smeor it with oil. Then
threod the clutch shoft through the ring to
instoll it into the splined bush ond put
it into
the housing together with the guide provided
with o cooting of seoling compound on its cyl-
indricol bedding surfoce. Secure both the shoft
ond the sleeve with circlips.
lnstoll the sleeve guide
with its droin hole
level with the porting plone
of the housing ond
focing the pinion.
For the speciol seoling compound see the
note in Chopter 10.1.
16. Put the pinion
with geors
into the housing
ond oil oll synchronizing rings. Fit the MP 5-104
iig for
setting the crown wheel bocklosh into
the bore of the differentiol beoning ond the
fitted cover, fit the ossembled differentiol in it,
ond close the housing with the other housing
holf ofter hoving cooted the seoling surfoces
with o seoling compound.
Fit o rubber ring in the recess of the boss
beside the stud
bolt ond put
o spring wosher
under the nut. Tighten the remoining nuts
without ony woshers (the
stress of the bolts
ofter the tightening of the nuts provides
for'
their suff icient securing). Tighten the nuts
moderotely for the time being.
For the speciol seoling
compound refer to the
note in Chooter 10.'1. 17.
Proceeding through
the bore of the differ-
entiol beoring in the upper holf of the housing,
fit another
iig, the MP
5-104,
on to the differen-
tiol with flonges clomped so os to fit
into the
topered roller beoring cover, locote the cover
pocking, ond fosten
the cover by meons
of three
nuts. lf the clomping or drowing close of the
flonges of this jig
proves inodequote, it is
necessory to drow close the flonges olso of
the
first, previously
inserted
iig.
18. Drive the guide
of the clutch throwout
sleeve into the housing using the MP 3-103 drift,
top home the drive shoft, ond insert
two od-
iusting woshers under the collor of the
pinion
shoft boll beoring on both holves of the housing
ofter hoving determined their thickness by
meosuring. Using o wire needle
inserted into
the holes of
the tobs of the woshers orronge the woshers so
thot they do not overlop the porting plone
of
the housing,
then instoll the cover ond spring
woshers, ond tighten the nuts (seeChopter
1.8).
19. Fosten the housing by tightening the nuts
(see Chopter 1.8) ond lock in position
the guide
of the clutch throwout sleeve with the respect-
ive clip using the spring wosher under the
clip
nuts.
4.3 ASSEMBLING
FINAL DRIVE
Ref itting Differentiol 20. Turn the housing into the horizontol pos-
ition. Rotote the ends of the knurled hondles
of the inserted iigs MP 5-104
to move the re-
instolled differentiol (see previous porogrophs
16 ond 17) until the crown wheel withdrows
Fig. 4.311- Adiusting
1 -
MP 5-104 iig,
3 -
MP 5-106
iig,Bevel
Geor Bocklosh
2 -
MP 5-101
iig,
4 -
Screwdriver from
the
Determir
swivellin
To rotr
iig with
tiol stor
21. Ins
on the b,
rotote th
the diol
ible to th
Retoin
ogoinst 1
cover. Tl'
teeth chc
losh on t
of the ho
wheel sic
fied volut
the hond
fully its c
( preferob
wheel). I
opened f1
respectivr
of the
iigr
Now tl"
iusted on
flonges o'
topered r
This situc
trot i o n.
Fig. a3fi
for tc
1
22. Rem
side (turn
withdrow
dimension hos to be
roller beori
Measuring 23. Unscr
the toperer
locote it o
q,
ry
80
Page 83 of 238
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Page 85 of 238
![SKODA 105S 1980 Owners Manual 98
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Page 86 of 238
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.(
Page 89 of 238
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-
Pressing-in Beoring Cups Using
MP 6-130 Jig
Fig.6.5/5 -
Instolling Seoling](/img/3/57421/w960_57421-110.png "SKODA 105S 1980 Owners Manual 1
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Fig.6.5/5
-
Pressing-in Beoring Cups Using
MP 6-130 Jig
Fig.6.5/5 -
Instolling Seoling")
1
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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
Page 112 of 238
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