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General instructions for repairing the gearbox > < Calculation of the gear ratio ?i?

Leon Mk1

General instructions for gearbox repairs
General instructions for gearbox repairs
To achieve a perfect and successful repair of the gearbox it is imperative to keep everything scrupulously clean and use the correct tools in perfect working order. When carrying out repairs bear in mind basic safety rules.
Here is a summary of general instructions for certain repair jobs, which would otherwise appear several times in the different sections of this Workshop Manual. Thus, these instructions must be taken into account for this Workshop Manual.
Gear change
t  Before fitting the gearbox to the engine, make sure that the dowel pegs between both elements are in good condition and correctly seated.
t  If the gearbox is replaced, fill with oil to the lower edge of the filling hole.
t  Filling levels and type of oil → Chapter.
Gaskets
t  Renew all o-rings.
t  Before applying sealing products (liquid gasket), clean all contact surfaces thoroughly and use -AMV 188 200 03- sealing paste.
t  Apply paste uniformly, not too thick.
Oil seals
   
t  Before fitting, coat lightly with gearbox oil on the outside surface and fill the space between oil lips with grease.
t  Once the oilseals are fitted, check the oil level and top up if necessary.
Safety locks
t  Renew all circlips, taking care not to stretch them excessively when fitting.
t  The circlips must be perfectly seated in their groove.
t  Renew all split pins.
  N32-0001
t  On fitting split pins, their groove must be longitudinal with respect to the trajectory of the force, as in the illustration.
Nuts and bolts
t  Loosen and tighten nuts and bolts on covers and casing in diagonal sequence.
t  For delicate parts, e.g. the clutch press, do not tilt them and always loosen the bolts gradually and in diagonal sequence.
t  The torque settings refer to non-oiled nuts and bolts.
t  All locknuts must be renewed.
Bearings
t  When new roller bearings are installed, they are to be installed as they come, without lubrication.
t  Needle bearings must be fitted with the thickest side plate facing the assembly tool.
t  All gearbox bearings will be fitted after having been lubricated with gearbox oil. Lubricate with special care to measure friction torque.
t  Bearings corresponding to the same shaft will be all replaced together. Use bearings from the same manufacturer as far as possible.
t  Bearings should be heated to 100 °C approx. before fitting. Use electric blower -SAT 1416- and the digital thermometer -SAT 4002- to check temperature.
t  Do not mix external tracks of the same size bearings, they are matched pairs.
Shims
t  Before fitting shims, check thickness measuring several points of the surface with a micrometer.
t  The existence of different thickness shims will enable the selection of the right one for the application.
t  Shims must not have lips or be damaged.
t  Only fit shims in perfect state.
Syncromesh rings
t  Do not mix up rings from different gears. If they are to be re-used, always fit to the same gear they came from.
t  Check for wear and replace if necessary.
t  On fitting coat with gearbox oil.
Gears
t  Before fitting clean thoroughly. First heat to 100 °C approx. Use electric blower -SAT 1416- and the digital thermometer -SAT 4002- to check temperature.
  V34-1515

General instructions for repairing the gearbox > < Calculation of the gear ratio ?i?