Power transmissionMain shaft: dismounting and assembling
| Main shaft: dismounting and assembling |
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| If it is necessary, assemble new pinions, consult section for Identification initials, assignation of groups, reductions, amounts for filling Group → Chapter. |
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| The main shaft must be adjusted whenever parts have been replaced that may affect the position of the tapered roller bearings. Consult the Adjustment Chart → Chapter. |
| 2 - | Outer track, tapered roller bearings |
| 3 - | Tapered roller bearing |
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| Position for assembly: the collar must remain facing towards the 4th gear pinion. |
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| Use tool -A-81124- for extracting the safety ring. |
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| Dismount it together with the tapered roller bearing → Item, the stop washer → Item and the sleeve for the needle bearing → Item, → Fig. |
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| Position for assembly: the collar must remain facing towards the 3rd gear pinion. |
| 8 - | Tapered roller bearing |
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| Dismount it together with the 4th gear pinion → Item, the stop washer → Item and the sleeve for the needle bearing → Item, → Fig. |
| 10 - | Outer track, tapered roller bearing |
| 13 - | Sleeve for needle bearing |
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| Dismount together with the 4th gear pinion → Item, the tapered roller bearing → Item and the stop washer → Item, → Fig. |
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| Before assembling it, put the stop washer into place → Item |
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| Dismount it together with the 5th gear synchroniser unit → Chapter |
| 16 - | 5th gear synchroniser ring |
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| Position for assembly → Fig. |
| 20 - | Movable sleeve for 5th gear |
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| Position for assembly: the concave side must remain facing towards the 5th gear pinion → Chapter |
| 22 - | Bolt for attaching the 5th gear pinion. 80 Nm |
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| The head of the bolt has a slot for housing the plate spring → Item |
| Special tools and workshop equipment required |
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| Case for extractors for gearboxes -U-40100- |
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| Gearbox repair case -U-40200- |
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| Pliers for opening elastic rings -A-81124- |
| Dismounting the outer track of the tapered roller bearing |
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| Dismounting the outer track of the tapered roller bearing from the main shaft in the clutch casing using tool -U-40200/20-. |
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| Assembling the outer track of the tapered roller bearing |
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| Assemble the outer track of the tapered roller bearing for the main shaft in the clutch casing, using tool -U-40200/10- and tool -U-40200/11-. |
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| Dismounting the tapered roller bearing |
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| Place the tool -U-40100/4- between the bearing and the main shaft pinion. |
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| Place the main shaft on tool -U-40100/4-, as shown on the drawing. Work the press in order to extract the bearing. |
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| Assembling the tapered roller bearing |
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| Assemble the bearing over the main axle using tool -U-40100/3- with the help of a press. |
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| Place the main shaft with the tapered bearing over the base of the tool -U-40100/3-, as shown in the drawing. Operate the press until the bearing is mounted in its position. |
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| Dismounting the 4th gear pinion, the tapered roller bearing, the stop washer and the sleeve for the needle bearing |
| The 4th gear pinion is dismounted together with the tapered roller bearing, the stop washer and the sleeve for the needle bearing. |
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| Assemble the tool -U-40100/3- in the main shaft, underneath the 4th gear pinion. |
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| Put the main shaft and the tool -U-40100/3- over the press as shown in the drawing. |
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| Work the press until the tapered roller bearing and the 4th gear pinion and the stop washer remain outside of the coupling. |
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| Dismounting the 3rd gear pinion |
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| Assemble the tool -U-40100/3- in the main shaft, underneath the 3rd gear pinion. |
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| Put the main shaft and the tool -U-40100/3- over the press as shown in the drawing. |
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| Work the press until the 3rd gear pinion is removed from the main shaft. |
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| Assembling the 3rd gear pinion |
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| Assemble the tool -U-40100/3- underneath the 3rd gear pinion. |
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| Place the tool -U-40100/3- with the pinion in a press, as shown in the drawing. Assemble the main shaft inside the pinion. The cogs of the pinion and the main shaft should match. |
| The collar of the pinion should remain facing towards the 4th gear pinion. |
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| Work the press until the pinion remains assembled in its position. |
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| Assembling the 4th gear pinion |
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| Assemble the tool-U-40100/3- underneath the 4th gear pinion. |
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| Place the tool -U-40100/3- with the 4th gear pinion in a press, as shown in the drawing . Assemble the main shaft inside the pinion. The cogs of the pinion and the main shaft should match. |
| The collar of the pinion should remain facing towards the 3rd gear pinion. |
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| Work the press until the pinion remains assembled in its position. |
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| Assembling the tapered roller bearing |
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| Assemble the tool -U-40100/3- over the base of the 2nd gear pinion and the main axle. |
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| Put the stop washer into place before placing the sleeve for the needle bearing. |
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| Put the tool -U-40100/3- on the press as is shown in the drawing. |
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| Fit in the tapered roller bearing, using tool -U-40200/19-. Work the press until the bearing is assembled in its position. |
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| Assembling the sleeve for the needle bearing |
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| Assemble the tool-U-40100/3- over the base of the 2nd gear pinion and the main axle. |
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| Place the shaft of the main axle with the 2nd gear pinion and tools -U-40100/3- and -U-40300/8- on a press as is shown in the drawing. |
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| Work the press until the sleeve is mounted in its position. |
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| Dismounting the outer track of the tapered roller bearing |
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| Extract the outer track of the tapered roller bearing of the main shaft in the gearbox casing using tool -U-40200/10-. |
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| Assembling the outer track of the tapered roller bearing |
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| Assemble the outer track of the tapered roller bearing for the main shaft in the gearbox casing using tool -U-40200/10- and tool -U-40200/11-. |
Note! | If the main shaft has been adjusted, the stop washer must be assembled before assembling the outer track for the tapered roller bearing. |
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| Assembling the 5th gear synchroniser unit |
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| Assemble the 5th gear synchroniser unit by carrying out the following steps: |
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| Place the movable sleeve -2- over the synchroniser sleeve -3- in such a way that the trimmings coincide -Afor housing the block pins -4- for both components and that the pointed cogs of the movable sleeve are situated in the same direction as the most pronounced edge -B-of the bushing. |
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| Assemble the blocking pins -4- and fix them in place with the springs -1- spreading them out 120º away from each other and under the projections of the blocking pins. |
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| Assemble the springs in the 5th gear synchroniser unit |
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| Check that the pointed cogs -A- of the movable sleeve are facing in the same direction as the most pronounced boss -B- of the bushing. |
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| Check that the blocking pins are assembled correctly → Fig.. |
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| Place the springs spread out 120º from each other, underneath the projections -C- of the blocking pins. The bent ends of the springs -arrows- must be located outside of the pins for blocking. |
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01 Transmission
The same page in:
Leon Mk2.
