Leon Mk2
| Assembly overview - output shaft for 1st and 2nd gear |
Note| t | Output shaft is not available as a spare part. |
| t | If tapered roller bearing is renewed, install new shims of the same thickness as the old ones. |
| 1 - | Clutch housing |
| 2 - | Oil deflector ring |
| 3 - | Shim |
| q | Note thickness |
| q | Will be damaged when removed; renew |
| 4 - | Tapered roller bearing outer race |
| q | Pulling off → Fig. |
| q | Driving in → Fig. |
| 5 - | Inner ring and roller bearing unit |
| q | Driving out → Fig. |
| q | Driving in → Fig. |
| 6 - | Dished washer |
| q | Pulling off → Fig. |
| q | Driving in → Fig. |
| 7 - | Output shaft |
| q | For 1st and 2nd gear. |
| 8 - | Thrust washer |
| q | For needle bearing |
| q | Removing from output shaft → Fig. |
| q | Driving in → Fig. |
| 9 - | Needle thrust bearing |
| q | Installation position → Fig. |
| 10 - | Needle bearing |
| q | For 1st gear |
| 11 - | Synchromeshed gear for 1st gear |
| q | With idler gear for reverse gear on opposite side |
| 12 - | Synchro-ring |
| q | (Inner ring for 1st gear) |
| q | Check for wear → Fig. |
| q | Check lugs for scoring |
| q | Installation position → Fig. |
| 13 - | Outer ring for 1st gear |
| q | Renew if scored |
| q | Installation position → Fig. |
| q | Fit to the synchro ring → Item |
| 14 - | Synchro-ring for 1st gear |
| q | Check for wear → Fig. |
| q | Installation position → Fig. |
| 15 - | Needle thrust bearing |
| q | Installation position → Fig. |
| 16 - | Locking collar with synchro-hub for 1st and 2nd gears |
| q | After removing retaining ring → Item, press off with 1st gear synchromeshed gear → Fig. |
| q | Dismantling → Fig. |
| q | Assemble the mobile element and synchromesh body → Fig. |
| q | Installation position → Fig. |
| q | Driving in → Fig. |
| 17 - | Retaining ring |
| 18 - | Needle bearing |
| q | For 2nd gear |
| 19 - | Synchro-ring for 2nd gear |
| q | Check for wear → Fig. |
| q | Fit so that the grooves insert in the locking elements of the mobile sleeve → Item |
| 20 - | Outer ring for 2nd gear |
| q | Renew if scored |
| q | Installation position → Fig. |
| q | Insert in synchro-ring → Item |
| 21 - | Synchro-ring |
| q | (Inner ring for 2nd gear) |
| q | Check lugs for scoring |
| q | Check for wear → Fig. |
| q | Installation position → Fig. |
| 22 - | Synchromeshed gear for 2nd gear |
| q | Installation position → Fig. |
| 23 - | Inner ring and roller bearing unit |
| q | Pull off with 2nd gear synchromeshed gear → Fig. |
| q | Driving in → Fig. |
| 24 - | Retaining ring |
| 25 - | Tapered roller bearing outer race |
| q | Pulling off → Fig. |
| q | Driving in → Fig. |
| 26 - | Shim |
| q | Note thickness |
| q | Will be damaged when removed; renew |
| 27 - | Gearbox housing |
