Leon Mk1
Layshaft: dismantling and assembling |
Special tools and workshop equipment required |
t | Gearbox extractor set -U-40100- |
t | Gearbox repair set -U-40200- |
t | Gearbox repair set -U-40300- |
t | Circlip opening pliers -A-81124- |
Note!
t | Whenever new gears or a new layshaft are fitted consult the technical data → Chapter, Code letters, group numbers, ratios, filling quantities. |
t | If the layshaft or the roller bearings are replaced, the layshaft must be adjusted → Chapter. |
t | The layshaft must be adjusted whenever elements have been replaced which could affect the position of the roller bearings. Refer to Adjustment chart → Chapter. |
1 - | Hexagon nut |
q | 25 Nm + 90° |
q | 4 units |
q | To secure the bearing housing |
2 - | Clutch housing |
q | Repairing → Chapter |
3 - | Shim |
q | For the layshaft |
q | Determine thickness → Chapter, Layshaft: adjusting |
4 - | Outer track, roller bearings |
q | Remove → Fig. |
q | Fit → Fig. |
5 - | Small roller bearing |
q | Remove → Fig. |
q | Fit → Fig. |
6 - | Layshaft |
q | A matched pair with the driveshaft gear; they must be replaced together |
q | In case of replacement → Chapter, Code letters, group numbers, ratios, filling quantities |
q | Adjusting → Chapter |
7 - | Large roller bearing |
q | Remove → Fig. |
q | Fit → Fig. |
8 - | O-ring |
q | 4 units |
q | Always renew |
q | For the securing bolts of the bearing housing → Item |
9 - | Bearing housing |
q | With outer track of the large roller bearing → Item |
q | The external track should only be replaced together with the large roller bearing and the bearing housing |
10 - | Stop washer |
q | The step of the shim should be facing the roller bearing |
11 - | Sliding 1st gear |
q | Before fitting the 1st gear, fit the stop washer → Item |
12 - | Needle roller bearing |
q | For the sliding 1st gear |
13 - | Synchronised ring for 1st gear |
q | Identification → Fig. and → Fig. |
q | Checking for wear → Fig. |
q | Check that the tabs show no signs of wear |
14 - | Syncromesh assembly for 1st and 2nd gear |
q | Remove → Fig. |
q | Dismantling → Fig. |
q | Assembling the components → Fig. and → Fig. |
q | Installation position → Fig. |
q | Fit → Fig. |
15 - | Safety ring |
q | Use tool -A-81124- to remove the circlip |
q | Always renew |
16 - | External syncromesh ring 2nd gear |
q | Identification → Fig. and → Fig. |
q | Checking for wear → Fig. |
q | Assembly position: The cut-outs of the syncromesh ring must fit with the locking keys in the 1st and 2nd gear syncromesh assembly → Item |
17 - | Intermediate syncromesh ring 2nd gear |
q | Place in the external syncromesh ring 2nd → Item |
q | Installation position → Fig. |
q | Replace if it shows signs of wear or grooves |
18 - | Internal syncromesh ring 2nd gear |
q | Identification → Fig. and → Fig. |
q | Checking for wear → Fig. |
q | Check that the tabs show no signs of wear |
q | Installation position → Fig. |
19 - | Sliding 2nd gear |
q | Installation position → Fig. |
20 - | Needle roller bearing |
q | For sliding 2nd gear |
21 - | Stop washer |
22 - | Needle bearing bush |
q | Remove together with sliding 2nd gear → Fig. |
q | Fit → Fig. |
23 - | Needle roller bearing |
q | For sliding 3rd gear |
24 - | Sliding 3rd gear |
25 - | Syncromesh ring 3rd gear |
q | Checking for wear → Fig. |
26 - | 3rd and 4th syncromesh assembly |
q | Remove → Fig. |
q | Dismantling → Fig. |
q | Assemble → Fig. and → Fig. |
q | Installation position → Fig. |
q | Fit → Fig. |
27 - | Needle bearing bush |
q | Remove together with the synchromesh 3rd and 4th gear assembly → Item |
q | Fit → Fig. |
28 - | Needle roller bearing |
q | For sliding 4th gear |
29 - | Syncromesh ring for 4th gear |
q | Checking for wear → Fig. |
30 - | Sliding 4th gear |
31 - | Stop washer |
32 - | Needle roller bearing |
q | For layshaft |
q | Removing and fitting → Chapter, Gearbox casing and clutch casing: repairing |
33 - | Gearbox casing |
34 - | Needle bearing bush |
q | Remove → Fig. |
q | Fit → Fig. |
35 - | Sliding 5th gear |
q | Removing and fitting → Chapter, Gearbox casing and 5th gear cover removing and installing |
36 - | Plate spring |
q | Assembly position: the concave side should be facing the sliding 5th gear |
37 - | Securing screw for sliding 5th gear |
q | The screw head incorporates a housing for the plate spring → Item |
q | Assembly → Chapter,Gearbox casing and 5th gear cover removing and installing |
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Syncromesh ring | Measurement “a” on a new syncromesh | Wear limit |
1st gear 3rd gear 4th gear | 1.0 ... 1.7 mm | 0.5 mm |
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Syncromesh ring | Measurement “a” on a new syncromesh | Wear limit |
2nd gear | 1.2 ... 1.8 mm | 0.5 mm |
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Syncromesh ring | Measurement “a” on a new syncromesh | Wear limit |
2nd gear | 0.75 ... 1.25 mm | 0.3 mm |
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