Power transmissionGearbox: Dismantling and assembling
| –
| Drain gearbox oil. Unscrew oil drain plug from gearbox. |
|
|
|
| –
| Remove clutch release bearing -B- and release fork -A-. |
Note! | Remove the guide bush securing bolts with the correct diameter of tool -U-40020-. |
|
|
|
| –
| Remove the right and left flanged shafts. |
| –
| Remove the flanged shafts with pressure springs, thrust washers and conical rings. |
|
|
|
| –
| Unscrew the gearbox casing cover and remove the gasket. |
| –
| Bolt the connection finger or tool -U-40203- to the connection shaft. |
|
|
|
| –
| Loosen the counter nut -arrow 1- located under the 5th gear connection fork. |
| –
| Remove the dome headed bolt -arrow 2- and remove the connection fork with the 5th gear sliding sleeve. |
|
|
|
| –
| Fit the sliding sleeve of the 5th gear on the syncromesh body. |
| –
| Remove bolt -A- for the 5th gear. To lock it, select 5th gear by hand by pushing the slider -arrow 1- and select 2nd gear with the selector -arrows 2- and -3-. |
| –
| After selecting the gears, the input and layshafts are locked, the body of the syncromesh and the gear cannot move and thus it is possible to loosen the bolt. |
| –
| Remove 5th gear sleeve and remove 2nd gear. |
|
|
|
| –
| Remove safety ring -arrow- from the syncromesh body of the 5th gear. |
Note! | Use tool -A-81124- to remove the safety ring. |
|
|
|
| –
| Remove the syncromesh body and the sliding 5th gear with tool -U-40100/1-. |
| –
| Remove the needle bearing for sliding 5th gear. |
|
|
|
| The 5th gear bearing bush will only be removed if the needle roller bearing needs to be replaced, proceed as follows: |
| –
| Heat the bearing bush to about 100 °C with the electric blower -SAT 1416-. |
|
|
|
| –
| Remove the thrust washer located under the needle bearing bush. |
|
|
|
| –
| Separate the clip -arrow- from the 5th gear control rod. Compress with pliers and pull in the direction of the layshaft. |
|
|
|
| –
| Separate the speedometer sender -arrow-. |
|
|
|
| –
| Remove the bolts securing the clutch housing from the gearbox casing. |
| –
| Separate both casings by tapping with a plastic hammer. No not damage the contact surfaces. |
| –
| Remove the differential from the gearbox casing. |
|
|
|
| –
| Remove the connection shaft cap -A- with tools -U-40200/25- and -U-40200/21-. |
|
|
|
| –
| Remove the connection shaft with a drift. |
|
|
|
| –
| Remove the spring -arrow- between the selector finger -A- and the gear console -B-. |
| –
| Remove the selector finger -A-. |
|
|
|
| –
| Remove the bolt -arrow- and remove the gear console and the bush. |
|
|
|
| –
| Remove the reversing light switch -1- and the bolts -2-, -3- and -4-. |
|
|
|
| –
| Remove the control rod for the 5th gear -1- and the reverse gear control rod -2- together with the coupling rod -3-. |
|
|
|
| –
| Remove the reverse gear shaft from the gearbox casing from the bottom; if necessary use tools -U-40200/3- and -U-40200/10-. |
|
|
|
| –
| Remove input shaft -5-, control rod and fork for 3rd and 4th gears -6-, the reverse gear shaft -1-, the reverse gear -2-, as well as the secondary shaft -4- and the control rod with fork for the 1st and 2nd gears -3-. |
|
|
|
01 Transmission
The same page in:
Leon Mk2.
