Leon Mk1
Secondary shaft: assembly overview |
Note
t | When installing new gears or a output shaft, see technical data → Chapter, Identification letters, group allocation, ratios, filling quantities |
t | If the layshaft or 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 - | Conical hexagon bolt |
q | 25 Nm + 90° |
q | 4x |
q | To secure the bearing housing |
2 - | clutch housing |
q | Repairing → Chapter |
3 - | Shim |
q | For secondary shaft |
q | Determining thickness → Chapter |
4 - | Small tapered roller bearing outer race |
q | Removing → Fig. |
q | Installing → Fig. |
5 - | Small roller bearing |
q | Removing → Fig. |
q | Installing → Fig. |
6 - | Output shaft |
q | Paired with final drive gear wheel. Always renew as a set. |
q | In case of replacement → Chapter, Code letters, group allocation, ratios, capacities |
q | Adjusting → Chapter |
7 - | Large roller bearing |
q | Removing → Fig. |
q | Installing → Fig. |
8 - | Sealing ring |
q | 4x |
q | Always replace |
q | For the securing bolts of the bearing housing → Item |
9 - | Bearing housing |
q | With large primary shaft bearing outer track → Item |
q | The external track should only be replaced together with the large roller bearing and the bearing housing |
10 - | Thrust washer |
q | Shoulder of thrust washer faces tapered roller bearing |
11 - | 1st speed selector gear |
q | Before fitting the gear pinion of the 1st gear, install the thrust washer → Item |
12 - | Needle bearing |
q | for the 1st gear mobile pinion |
13 - | Synchro-ring for 1st gear |
q | Identification → Fig. |
q | Checking for wear → Fig. |
q | Check that the tabs show no signs of wear |
14 - | Synchronising hub for 1st and 2nd gear |
q | Removing → Fig. |
q | Dismantling → Fig. |
q | Assembly of components → Fig. and → Fig. |
q | Installation position → Fig. |
q | Installing → Fig. |
15 - | Circlip |
q | Use pliers -A 81124- to remove the safety ring. |
q | Always replace |
16 - | Outer synchroniser ring for 2nd gear |
q | Identification → Fig. |
q | Checking for wear → Fig. |
q | Fitting position: the grooves in the synchromesh ring must fit with the pins in the synchromesh assembly of 1st and 2nd gear → Item |
17 - | Middle synchroniser ring for 2nd gear |
q | Fit into the outer synchromesh ring of the 2nd gear → Item |
q | Installation position → Fig. |
q | Replace if it shows signs of wear or grooves |
18 - | Inner synchroniser ring for 2nd gear |
q | Identification → Fig. |
q | Checking for wear → Fig. |
q | Check that the tabs show no signs of wear |
q | Installation position → Fig. |
19 - | 2nd speed selector gear |
q | Installation position → Fig. |
20 - | Needle bearing |
q | For 2nd gear mobile pinion |
21 - | Thrust washer |
22 - | Needle bearing bush |
q | Remove together with the mobile pinion of 2nd gear → Fig. |
q | Installing → Fig. |
23 - | Needle bearing |
q | For the 3rd gear selector gear |
24 - | 3rd speed selector gear |
25 - | Synchromesh ring 3rd gear |
q | Identification → Fig. |
q | Checking for wear → Fig. |
26 - | Synchromesh body of 3rd and 4th gear |
q | Removing → Fig. |
q | Dismantling → Fig. |
q | Assemble → Fig. and → Fig. |
q | Installation position → Fig. |
q | Installing → Fig. |
27 - | Needle bearing bush |
q | Remove together with the synchromesh assembly of the 3rd and 4th gear → Item |
q | Installing → Fig. |
28 - | Needle bearing |
q | For 4th gear mobile pinion |
29 - | Synchroniser ring for 4th gear |
q | Identification → Fig. |
q | Checking for wear → Fig. |
30 - | 4th speed selector gear |
31 - | Thrust washer |
32 - | Needle bearing |
q | For secondary shaft |
q | Removing and fitting → Chapter, Gearbox housing and clutch housing: repairs |
33 - | Gearbox |
34 - | Needle bearing bush |
q | Removing → Fig. |
q | Installing → Fig. |
35 - | 5th gear mobile pinion |
q | Installation → Chapter, Gearbox housing cover and 5th gear: Removing and installing |
36 - | Dished washer |
q | Fitting position: The concave side should be facing the selector gear for the 5th gear |
37 - | Attachment bolt of 5th gear mobile pinion |
q | The screw head incorporates a housing for the plate spring → Item |
q | Fitting → Chapter, Gearbox housing cover and 5th gear: Removing and installing |