Skoda Felicia

since 1994 release

Repair and operation of the car



Skoda Felicia
+ Cars of the Skoda Felicia brand
+ Maintenance instruction
+ Routine maintenance
+ Repair of the engine
+ Cooling systems, heating
+ Power supply system
+ Engine electric equipment
+ Coupling
- Transmission
   General information
   Description of knots and mechanisms
   Removal and installation of drafts of the drive of gear shifting
   Replacement of epiploons
   Check of serviceability of functioning, removal and installation of the sensor-vyklyu-chatelya of fires of a backing
   Removal and installation of the mechanism of the drive of a speedometer
   Removal and installation of the transmission
   Capital repairs of RKPP, dismantling and assembly of knots and components
+ Power shafts
+ Brake system
+ Suspension bracket and steering
+ Body and finishing of salon
+ Onboard electric equipment





Capital repair of RKPP, dismantling and assembly of knots and components

Gear shifting mechanism drive components

1 — RKPP control lever Handle
2 — RKPP Control lever
3 — the External protective cover
4 — the Internal protective cover
5 — the Jet bar
6 — the Rubber emphasis
7 — the Fixing collar
8 — the Bolt
9 — the Expansion plug
10 — the Lock ring
11 — the Remote washer
12 — Rubber rings
13 — Plugs of the spherical hinge
14 — the Boot

15 — M6 Bolt
16 — the Washer
17 — the Rubber plug
18 — the Washer
19 — Draft of the drive of gear shifting
20 — the Cardan hinge
21 — the Connecting coupling
22 — the Pin
23 — Plastic plugs
24 — a bolt
25 — a draft Collar
26 — the Spring washer
27 — M8 Nut (18 Nanometers)
28 — the Pin


Components of assembly of a gear wheel of the 5th transfer of RKPP

1 — the Adjusting washer
2 — the Separator of the needle roller bearing of a gear wheel of the 5th transfer
3 — the Internal holder of the bearing
4 — the Leading gear wheel of the 5th transfer
5 — the Conducted gear wheel of the 5th transfer
6 — the Nut (60 Nanometers)
7 — the Blocking synchronizer ring
8 — Pruzhina of the synchronizer
9 — the Nave of the sliding synchronizer coupling

10 — the Sliding synchronizer key
11 — the Nut (60 Nanometers)
12 — the Washer
13 — the Basic ring
14 — the Sliding synchronizer coupling
15 — Pruzhina of the synchronizer
16 — the Fork of inclusion of the 5th transfer
17 — the Pin 5х22 (is subject to replacement without fail)


Order of installation of components of assemblies of primary and secondary shaft of RKPP

1 — a coupling Dome
2 — Assembly of the main transfer
3 — Assembly of a secondary shaft
4 — the Rod of a fork of inclusion of the 5th transfer
5 — the Rod of forks of inclusion of 1/2 and 3/4 transfers
6 — Assembly of a main shaft
7 — the Pin 4х7

8 — the Pin of the lever of inclusion of a backing
9 — the Cap
10 — the Lever of inclusion of a backing
11 — a clamp Ball
12 — the Lock spring
13 — the Intermediate gear wheel of a backing
14 — the Pin


Main shaft of the transmission

1 — the Internal holder of the conic roller bearing
2 — the External holder conic roller to bearings
3 — the Remote washer

4 — the Main shaft
5 — the Internal holder of the conic roller bearing
6 — the External holder of the conic roller bearing


Components of a secondary shaft of a box of RKPP

1 — the Lock ring
2 — the Ball-bearing
3 — the Gear wheel of the 4th transfer
4 — Pruzhina of the synchronizer
5 — the Sliding synchronizer key
6 — the Nave of the sliding synchronizer coupling
7 — the Sliding synchronizer coupling

8 — the Lock ring
9 — the Blocking synchronizer ring
10 — Assembly of the synchronizer 3/4 of transfers
11 — the Gear wheel of the 3rd transfer
12 — the Washer
13 — the Adjusting washer of 2/3 transfers
14 — Pruzhina of the synchronizer


Gear shifting mechanism components

1 — the Sleeve of a rod of a fork of inclusion of transfers
2 — the Coupling
3 — the Pin 5х22 (at assembly is subject to replacement without fail)
4 — the Fork of inclusion of 1/2 transfers
5 — a gear shifting mechanism Thorn
6 — a clamp Cracker
7 — the Rod of forks of inclusion of 1/2 and 3/4 transfers
8 — the Fork of inclusion of 3/4 transfers
9 — a rod Sleeve
10 — the Lock bolt
11 — the Fork of inclusion of the 5th transfer
12 — the Rod of a fork of inclusion of 5-1 transfer
13 — the Thorn of the mechanism of switching of the 5th and back transfers
14 — the Directing coulisse
15 — Laying
16 — the Bolt (10 Nanometers)
17 — the Trekhplechy lever

18 — the Pin of the trekhplechy lever
19 — the Carving stopper with an internal hexagon (30 Nanometers)
20 — the Bolt (17 Nanometers, before installation to grease with sealant like Loctite)
21 — the Executive lever of a rod of the choice of transfers
22 — a coulisse Finger
23 — the Pin with a spring
24 — the Pin with a spring
25 — the Rod of the choice of transfers
26 — the Sealing ring of a rod of the choice
27 — the Boot
28 — the Lock spring
29 — a clamp Ball
30 — the Finger of the lever of turning on of the reverse gear
31 — the Lever of turning on of the reverse gear
32 — the Cap
33 — the Pin 4х25


Capital repairs - the general information

Capital repairs of RKPP demand from the performer of high skill level as it assumes performance of exact exposure of a set of gaps, by selection of adjusting washers and remote plugs. Besides, it is rather difficult to find internal components of the transmission on free sale, not to mention the high prices of them. In view of everything told, authors of the present manual recommend in case of problems in functioning of RKPP to make replacement it on the new or restored block.

Nevertheless, rather skilled amateur mechanic without effort can execute repair of the transmission by own forces on condition of existence of the special tool. Remember that all procedures have to be performed strictly as appropriate. You do not hurry, fuss, try to pass any trifles.

In number of special tools without which use repair of RKPP becomes impossible nippers for extraction of external and internal lock rings, a set of strippers, the hammer with sliding brisk, a set of drifts, the dial measuring instrument of plunger type and, whenever possible, hydraulic press belong. Besides, the workplace has to be equipped with a big strong workbench with a vice.

In the course of dismantling of the transmission it is necessary to fix carefully on paper the adjusting provision of all removed components for the purpose of a guarantee of correctness of placement them at assembly.

Before starting dismantling of RKPP it is necessary to try to define for itself the possible reasons of the violations taking place. Some problems are rather accurately tied to concrete knots of the transmission that allows to reduce significantly time for identification and elimination of defects.

Gear shifting mechanism drive

Dismantling and assembly of a control lever of RKPP

 PERFORMANCE ORDER

1. Components of assembly of the drive of the mechanism of gear shifting are presented on an illustration. All references given below correspond to the numbering accepted on this illustration (if other is not stipulated separately).
2. Remove the handle of a control lever (1).
3. Release from the panel of the central console and remove from the lever an external protective cover (3).
4. Give a fixing nut and take a bolt (15) of fastening of a control lever to draft of the drive of gear shifting.
5. Give fixture of fixing of a jet bar (5) of the lever on a body and a case of RKPP.
6. Remove the lower protection cover of the lever (4).
7. Lower down and remove from the car assembly of a jet bar with a control lever.
8. Remove a lock ring (10) and a remote washer (11).
9. Having hooked the suitable peaked tool, take from a landing flute in the top plug of the spherical hinge (13) of edge of a rubber sealing ring (12) and knife it. Then use flat-nose pliers and take the cut ring from a flute.
10. Having hooked the screw-driver, remove from below a rubber boot (14).
11. Take the lower rubber sealing ring of vtulochny assembly.
12. From below squeeze out assembly of a control lever together with hinge plugs of a jet bar.
13. Assembly is made in the return sequence.


Removal of a cover of a case of RKPP, dismantle of a support

 PERFORMANCE ORDER

Removal of a cover can be made also in situ (directly on the car).

1. Fix assembly of RKPP at the assembly stand.

2. It is uncovered assembled with a support of the power unit. In a diagonal order weaken and turn out fixing bolts.

1 — the Cover
2 — the Rubber-metal plug of a support of the power unit
3 — Bolts of fastening of a cover (25 Nanometers)

3. Remove assembly of a cover with a support of the power unit from a transmission case.
4. Remove forward and back assembly brackets of assembly of a support of the power unit.

5. By means of MP 3-601 adaptation squeeze out the rubber-metal plug of a support of a cover of a case of RKPP.

6. At installation a rubber-metal support have to it is developed as shown in an illustration.

7. Zapressovyvany plugs it is made by means of MP 3-602 adaptation.

8. Establish a forward assembly bracket of fastening of a support (without the welded nuts) from a starter, and back (with the welded nuts) - from the opposite side. Tighten a fixing bolt so that assembly brackets fell into the top state and were not turned. Final tightening of a bolt is made after installation of a box of transfers / the power unit on the car.

1 — the Forward assembly bracket of a support
2 — the Back assembly bracket of a support
3 — the Fixing bolt (50 Nanometers)

Dismantle and installation of reduktorny assembly of the 5th transfer

 PERFORMANCE ORDER

Dismantle of a gear wheel of the 5th transfer can be made without removal of a box from the car. At the same time it is necessary to block the unit by means of MP 9-502/1 adaptation.


1. Block main shaft RKPP from a provorachivaniye by means of MP 3-502 adaptation. If the box is not removed from the car, blocking of a shaft is made by inclusion of the 4th transfer.

2. Give a nut of fastening of the conducted gear wheel by means of MP 3-603 adaptation.

At assembly the nut is subject to replacement without fail.

3. Working in a similar manner, give a nut of fastening of the leading gear wheel of the 5th transfer on a main shaft.

4. Beat out a fixing pin...

... also remove a fork of inclusion of the 5th together with the sliding synchronizer coupling. Try not to drop the sliding keys, at once having taken out them from the grooves in a nave.

5. Consistently remove components of reduktorny assembly of the 5th transfer from both shaft.

6. Installation is made upside-down. At installation of the synchronizer the accuracy of installation of the sizes of a nave of the sliding coupling is of particular importance. Under control parameter is the size and, defining distance from an end face of the leading gear wheel to a basic surface of blocking synchronizer ring. Measurement is performed by means of the dial measuring instrument of plunger type to which fixing on assembly MP 3-535 adaptation is used. Synchronizers of three dimensional groups are issued:

and = 2.75 ÷ 3.10 (mm)
and = 3.11 ÷ of 3.44 (mm)
and = 3.45 ÷ 3.78 (mm)

1 — the Dial measuring instrument
2 — a synchronizer Ring
3 — the Leading gear wheel
4 — the MT Tool 3-535
5 — the Shaft


Dismantle and installation primary/secondary shaft of RKPP and assembly of the main transfer

 PERFORMANCE ORDER

1. The order of installation of components of primary and secondary shaft in the transmission is shown on an illustration.
2. Dismantle reduktorny assembly of the 5th transfer.

3. Unclench and take a lock ring of the ball-bearing. Take away a shaft against the stop in a coupling case.

4. Turn out the lock screw.
5. Turn out bolts of fastening of a dome of coupling to RKPP case.

6. By means of MP 3-503 adaptation separate a coupling dome from a case of RKPP and move away him aside.

7. As shift of the sliding synchronizer coupling assembled with a fork of inclusion choose the 4th transfer.

8. Turn a rod of a fork of inclusion of the 5th and the lever of inclusion back transfers approximately on 15 ° counterclockwise and take it from assembly.

9. Take assembly of an intermediate gear wheel of a backing together with its axis.

10. As shift of the sliding couplings of synchronizers together with forks of inclusion choose the 2nd and 4th transfers.

11. Take the remained assembly of a rod with forks of inclusion of transfers.
12. Take a main shaft and assembly of the main transfer from RKPP case.
13. Assembly is made in the return sequence.


Dismantling and assembly of shaft of RKPP

Main shaft


 PERFORMANCE ORDER

1. The order of installation of components of assembly of a main shaft is presented on an illustration.
2. The order of dismantle of bearings is shown on illustrations.

3. Installation is made in the return sequence.


Secondary shaft

 PERFORMANCE ORDER

1. The order of installation of components of assembly of a secondary shaft is presented on an illustration.
2. The order of dismantle of bearings of a secondary shaft is presented on illustrations.

3. Assembly is made in the return sequence. Zapressovyvaniye of the roller bearing of a secondary shaft is made by means of MP 3-513 adaptation. The blocking rings of synchronizers which were in the use have to be established on a shaft strictly on the former places. Before installation the blocking rings and bearings should be oiled plentifully gearbox. Before starting assembly of the conducted gear wheels of the 1st ÷ 4th of transfers, it is also necessary to grease the surfaces of their sliding with plentiful amount of oil. Try not to mix the sliding keys of synchronizers 1/2 and 3/4 of transfers at installation - they are not interchangeable.


Adjustment of gaps in bearings of a main shaft and differential

 PERFORMANCE ORDER

Before installation bearings and their landing surfaces need to be cleared carefully of dirt and to degrease.

1. By means of MP 3-511 adaptation press an external holder of the conic roller bearing against the stop in a coupling case.

2. In an opening under installation of a main shaft in a case of coupling fill MT adaptation 3-503/2 and put on it an external holder of the smaller bearing of the conic roller bearing of a main shaft.

3. Enclose in a coupling case assembly of the main transfer with the internal holders of bearings pressed to it.
4. Put on an external holder of the conic roller bearing of differential on internal and an external ring of MP 3-530/1 adaptation.
5. Screw against the stop fixing nuts of MP 3-530/1 and MP 3-530/2 devices (without leaving any gap).
6. By means of MP 3-511 adaptation press an external holder of the conic roller bearing of bigger diameter of a main shaft against the stop in RKPP case.
7. On a flange of a case of coupling install expansion plugs with a ledge. Struts should be installed on the opposite sides in a diagonal order.
8. Get a box case on struts and fix it by bolts with the washers attached in a set to the mentioned adaptation.
9. Having enclosed the remaining struts, also fix them by screws with washers.
10. Gradually improving screws in a diagonal order, tighten them with effort of 25 Nanometers, having recorded thereby a case of RKPP and MT adaptation 3-530.
11. Turn out an adjusting nut of MP 3-530/1 and MP 3-530/2 devices so that bearings of differential and a main shaft were turned with an easy resistance (without axial side play).
12. By means of the probes of lezviyny type put in gaps of adjusting nuts determine the sizes of necessary adjusting washers both for the main transfer, and for a main shaft. Adjusting washers of the following thickness are issued:

Differential: 2.0 ÷ 2.7 mm with a step of 0.1 mm
Main shaft: 0.20 mm, 0.25 mm, 0.30 mm, 0.36 mm, 0.60 mm and 0.80 mm


13. Having separated RKPP case from a coupling dome, take devices.
14. In an opening under installation of the bearing of differential in a case of RKPP establish necessary quantity of adjusting washers, trying to obtain the adjusting size of +0.20 mm.
15. By means of MP 3-511 adaptation put an external holder of the conic roller bearing of differential against the stop in RKPP case.
16. By means of MP 3-505 adaptation push out an external holder of the conic roller bearing of bigger diameter of a main shaft from a transmission case.
17. Under landing of the conic roller bearing of bigger diameter of a main shaft enclose adjusting washers according to the established size in RKPP case opening.
18. By means of MP 3-531 adaptation press an external holder of the bearing of bigger diameter of a main shaft against the stop it in RKPP case.

19. Check a differential bearing pretightness by means of MP 3-531 adaptation and a dynamometer key.


Dismantling and assembly of differential

 PERFORMANCE ORDER

Dismantling and assembly of differential is made by means of special tools.


Dismantling and assembly of the mechanism of gear shifting

 PERFORMANCE ORDER

1. The order of installation of components of the mechanism of switching is presented on an illustration.

2. Dismantling and assembly of the mechanism of gear shifting is made by means of special devices.

3. Assembly is made in the return sequence.


Adjustment of the trekhplechy lever of the mechanism of gear shifting

 PERFORMANCE ORDER

Deepening of an opening in an inclusion fork rod for fixing of the executive lever has to be directed up. The end of a finger of the coulisse should not adjoin to the coulisse when moving a rod of a fork of inclusion (it is reached by position of the executive lever)

1. Freely screw the bolt (2) which is previously greased with sealant like Loctite.

1 — the Executive lever of a rod of the choice of transfers
2 — the Bolt
3 — the Trekhplechy lever
4 — the Directing coulisse
5 — a coulisse Finger
6 — an inclusion fork Rod

2. Adjust the provision of the end of a finger of the coulisse so that to prevent its contact with the coulisse when moving a rod of a fork.
3. Tighten a bolt (2) with effort of 14 Nanometers.
4. The coulisse finger at assembly is subject to replacement in case of expression of boring under a pin with a spring.