lock SKODA 120 LS 1980 Owner's Manual

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

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

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.(

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

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
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98

5.5-5.7
the toe-in of the reor
wheels using olso the
MP 8-152 gouge or onother speciol gouge
ovoil-
oble in your
workshop. To
obtoin the required
shift of the holf-oxles (symmetricol
so os not
to
disturb the oxle olignment), strike ogoin the
holf-oxles with o rubber mollet
os per poro-
groph 2.
4" Retighten the slockened connections
(rodius orm bolts) ond, occording to the pro-
gress of the reossembly, olso the nuts of the
holf-oxle shoft (see
Chopter 5.2, porogroph
5).
Complete the operotion by locking the nuts.
Fig. 5.5/3 -
Checking Alignment of Reor Axle
with Cor Centre Line Using MP 8-158
Gouge 5.6 HALF.AXLE DUST BOOTS
To prevent
oil from leoking through the
ioint
gop between the dust boot ond the joint
guord
os well os ony twisting of the boot during
the oction of the rood spring, or its domoge by
contoct with other cor ports,
it is importont to
observe its correct position
on the holf-oxle. lt
should be locoted
with its
flonges focing
reor-
wqrd ond tilted upword ot on ongle of obout
45o. For better occess, ploce
the clips fostening
the dust boot to the holf-oxle ond cover with
their screws on top. With the right-hond
boot,
screw in the clip screws from the front,
with
the left-hond boot the screw on the holf-oxle
from the reor ond on the cover from the front.
Connect the dust boot flonges with hollow
rivets using suitoble pliers.
lf riveting pliers
ore
not ovoiloble, bolt the flonges togethen instol-
ling odequotely dimensioned ploin
woshers
under the bolt heods ond nuts.
5.7 HALF.AXLE SHAFT
The thrust ring of the beoring (behind
the
shoft toper) is pressed
on the shoft. lf it is ne-
cessory to renew this ring, for exomple ofter
repeoted replocements
of the beoring (see
Chopter 5.1, porogrroph
4), press
it on so
thot
it is removed 76 to 78 mm from the edge
of the
toper behind the shoft
threod.
100

*
Fir
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Fig.
6.1/4 -
Costor Angle
It is imperotive to set the
ongle with regord to
the direction of forword
trovel os indicoted
by the orrow
Fig.6.1/5-Preporing front oxle for the condition
of check lood by inserting
steel bors of 181 mm
in diometer ond obout
220 mm long
The most importont points
from the point
of
view of driving ore the
toe-in ond the comber
ongle, the odiustment of which is permitted
by
the oxle design.
Adiust first the comber
ond then the toe-in
since o chonged comber
offects the toe-in.
We refroin from describing in detoil ony
meosuring method in view
of the lorge number
of existing gouges.
Insteod,
we odvise you
to refer to
the procedures recommended
by the
monufocturers of the gouges.
The check lood con be formed by blocking the
wishbones with bors occording to
Fig. 6.1/5.
Press down the cor with the hond, insert
the
bors under the wishbones so
thot they
beor
ogoinst the oxle brocket, ond releose the cor
to
let the bors be clomped. lf
clomping of the
bors
does not toke ploce
(which con hoppen on on
older cor with weokened springs),
consider the
condition os if the bors were
clomped, i. e',
corresponding to the position of the
front oxle
ot check looding.
The words "ot
full lood" describe o vehicle
looded so thot the distonce of the rubber deod
stop from the bottom of the
lower wishbone
stop is 20 mm (see olso porogroph
18) ond the
comber ongle of the reor wheels is 1". Meosure
these volues on oll wheels (not
only one front
ond one reor wheel) ond distribute the
lood os
necessory.
Toe-in To odiust the toe-in, screw
the right-hond ond
left-hond steering rods
symmetricolly (o
chonge
up to 1 mm con be effected by
one rod) ot
check lood so thot the distonce between the
wheel rims (or
ocross them) behind the oxle
(A+o) is lorger by the toe-in volue (o)
thon the
distonce between the rims
in front of the oxle
(A). To verify steering symmetry (correct screw-
ing of steering rods during
toe-in odiusting),
check the wheel lock position ot the
20" lock
ongle of the neorside wheel -
for the respective
volues refer to Chopter 1.7.
Slocken the steering rod
nuts ond rotote the
steering rods using on
olligotor wrench (Fig.
6.1/6). In oddition to the correct inflotion
pressure
of the tyres, poy
ottention to
severol essentiol
points when checking the wheel
olignment:
o) Ploce thewheel in the stroight oheod trovel'
ling direction;
b) The
steering rod ond the trock rod
must
not
be stressed. The stress con be eliminoted by
letting the cor swing
up ond down in its
suspension under the pressure of
your
honds
(olternotely press down ond releose
the
wings)
c) Prepore the oxle os
shown in Fig.6.1/5;
d) lf
o speciol gouge with
o scole for wheel
lock ongle setting is ovoiloble, odiust
the cor'
rect length of steering rods in
occordonce with
the position
of wheels in
check lock positions.
You will find the respective volues
in Chopter
1.7 "Steering".
Set the lock ongle
of the wheel
on one
side to 20' (on
o turn-toble) ond screw
the steering
rod of the other wheel to odiust
104

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prl
tht
rer
oul MT
ott
rec
.a
Fig
Dis S
boll
6-1C
rubl
ovo
exomple
50,000 km ond
more, check the wheel
comber ond prepore
suitoble woshers for its
correction. 2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels. 3. Proceeding from
inside the luggoge boot,
remove covers protecting
the threods of the
shock-obsorber piston
rods ond screw off the
nuts. Retoin the piston
rod by holding its flot-
tened end.
b) Operotions inside the cor
4. Remove the steering wheel, the steering
column cowling, ond detoch the steering
shoft
from the body -
see Chopter 7.8.
c) Operotions from under the cor
5. Remove the bolt of the connection of the
steering shoftwith the steering box ond releose
the shoft sleeve from the connection by pull-
ing the steering geor
inside the cor.
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed. 7. Detoch the onti-roll bor brockets from
the
body ond disconnect the rubber broke hoses
from the front broke systems.
Before discon-
necting the hose, cleon thoroughly the hose
connector ond its surroundings to prevent
foreign motter from getting
into the broke
system. For the some reoson,
wrop the
hose
ends in o cleon rog. Toke
the some precoutions
with the disconnected broke piping.
8. Ploce o roll-o-cor
iock under the oxle ond
remove the bolts (two
on either side
of the tele-
scopic shock obsorber) fostening the oxle to
the body from obove. 9. Compress the telescopic shock obsorbers,
lower the
iock, ond
move it with the oxle from
under the cor.
6.3 REFITTING FRONT AXLE IN
CAR
1. To reinstoll the oxle in
the cor, reverse the
procedure of its removol, i.
e., begin with the
porogroph 9 ond proceed
to the porogroph
1.
Coot the rubber
cup with greose
ot the point
of its contoct with the steering shoft.
2. While reconnecting the broke hoses, ob-
serve the utmost cleonliness ond bleed the front
wheel brokes if no other ports
of the broke
system hos been dismontled. (lf
such o dis-
montling hos token ploce,
bleed the brokes of
oll wheels ofter hoving fully reclosed
the broke
circuit). 3. Turn the wheels in the stroight oheod di-
rection before connecting the steering shoft
with the steering box. Fit the steering wheel tentotively
ond odiust the direction indicotor
switch -
see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
into full lock positions
to moke sure thot the
lock ongle is correctly limited by the king pin
socket stops -
see Chopter 6.5, porogroph
36.
5. Adiust the toe-in -
see Chopter 6.1.
6.4 DISMANTLING
FRONT AXLE
No speciol instructions ore required for
dis-
montling mony of the subossemblies. Accord-
ingly, only the bosic dismontling procedure
will be
deolth with ond porticulors
will be men-
tioned only os fon
os they ore necessory for the
sequence of operotions ond the use of iigs.
Ports which con be dismontled witlrout re-
moving them from the cor ore the wheel hubs
and beorings, the broke mechonisms, steering
orms, shock obsorbers, ond the
onti-roll bor.
lf ony odditionol ports
hove to be dismontled,
remove the oxle from the cor ond dismontle it
on the stond.
Dismontling Wheel Hubs
ond Beorings
1. Dismontle the broke mechonism os per
Chopter 9.1 ond remove
the wheel hub
cop
using the MP 6-124 drog. When using the MP
6-136 pull-off
cortridge, the hub cop hos to be
prised off with o
tyre lever or o similor tool.
Now remove the costelloted nutwith its wosher
ond pull
out the hub,
ossisting the removol
with
light blows of o mollet, if necessory.
2. Toke out the inner port
of the outer beor-
ing, then the seoling ring, ond, f
inolly, the inner
port of the reor beoring (cone
with topered
rollers). Prise out the seoling ring using o
scrrewdriver. Proceed corefully olong the ring
circumference to ovoid distorting the ring which
Fig. 6.4/1 -
Removing Hub Cop Using
MP 6-124 Drog
106

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bo
Pock with
greose
the plostic
dust cup ond
press it over the nut till it snops home in po-
sition on the lever.
Refitting Upper Wishbones 4. When refitting wishbones
which hove
been olreody used in the cor ond which ore
rother doubtful (for
exomple,
o distortion is
suspected os o result of o crosh), inspect them
corefully ond stroighten
them, if necessory.
5. Press rubber bushes into the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol
or soop
woter (suds).
Put the
bushes into the wishbone eyes with their lorger
diometer first ond push
them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with com-
pressed oir so thot it does no ossist the slipping
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122 driIt,
dip the drift in petrol
or soop woter, ond, forcing
it through the rubber
bush, press
the spocing
tube into the bush.
Before pressing
it in, turn the spocing tube so
thot the
ioint of the
pockoged
bush foces the
top side of the wishbone.
7. Threod the wishbone pin
through the eye,
slip on it the cup with its dished port
focing
the bush, two wishbone brockets with the lugs
pointing owoy from the wishbone, ond the other
Fig.6.5/2 -
Pressing Spocing Tube
into
Bush Using MP 6-122 Drift cup with
its dished port
tbword the
other rubber
bush, ond threod the pin
through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port
of the
pin. To slip them on, hold them with their un-
connected ends on the pin
ond press
down. Use
o screwdriver to move one of the circlips into
the groove
of the pin,
ond push
the pin
with the
circlip in position
into the brocket. Clomp the
other brocket with the wishbone eye
in o vice
to compress the rubber bush, ond slip on the
other circlip. 9. lnsert the rubber deod stop into the wish'
bone.
Fig. 6.5/3- Instolling Circlip into Pin Groove
10. Reinstoll the
two ossenrbled wishbones
on the oxle body. Fit o ploin
wosher under the
spring woshers of the lug bolts. Instoll, from
obove, one 'l
mm or one 3 mm open (horseshoe)
wosher or the previously
removed woshers on
the horizontcrl bolts between the brocket ond
the oxle body lug. First tighten the horizontol ond then the ver-
ticol bolts. Fit the
cups on the wishbone pin
ond screw
down both nuts.
Refitting Lower Wishbones
11. Inspect the wishbones os per porogroph 4.
lnsert rubber bushes in
the eyes of the wish-
bone fnom its inner side. Threod the wishbone
pin through the eye, slip
on it the cup os with
the upper wishbone, then two pin
holders with
the recesses ot the inner hole focing eoch
other, onother cup, ond complete the operotion
by threoding the wishbone pin
through the
other eye. 12. Slip circlips on the wishbone pin
ond
lock with them the wishbone brockets in po-
sition. Proceed in the some monner os with the
upper wishbone (porogroph 8).
110
Rubber