Leon Mk1
Input shaft: dismantling and assembling |
Special tools and workshop equipment required |
t | Pliers -A-81124- |
t | Kit -T20140- |
t | Kit -U-40100- |
t | Kit -U-40200 A- |
Note!
t | Whenever new gears are fitted consult the technical data → Chapter. |
t | The input shaft must be adjusted whenever elements have been replaced which could affect the position of the roller bearings. Refer to Adjustment chart → Chapter. |
1 - | M8 Torx screw, 40 Nm |
2 - | Plate spring |
3 - | 5th gear |
q | Removing and installing → Chapter, assembly sequence |
4 - | Washer |
q | Always 1 mm thick |
q | Fitted to gearboxes manufactured from 07.97, except those bearing the letters DQW |
5 - | Outer track, roller bearing |
q | Remove → Fig. |
q | Fitting → Fig. |
6 - | Roller bearings |
q | Remove → Fig. |
q | Fitting → Fig. |
7 - | Gearbox casing |
q | In gearboxes manufactured from 07.97, except those bearing the letters DQW, and due to washer → Item the outer track of the roller bearing fits 1 mm lower |
8 - | Input shaft |
q | Adjust → Chapter |
9 - | Needle bearing |
q | Lubricate before fitting |
10 - | Sliding 3rd gear |
q | Remove → Fig. |
q | Fitting → Fig. |
q | It is fitted together with the sliding sleeve and the 3rd and 4th gear syncromesh hub |
11 - | Syncromesh ring 3rd gear |
q | Checking for wear → Fig. |
12 - | Safety ring |
q | Separation → Fig. |
q | Location → Fig. |
13 - | 3rd and 4th syncromesh assembly |
q | They are matching pairs |
q | Separation → Fig. |
q | Assemble → Fig. |
q | Fitting the input shaft → Fig. |
14 - | Safety ring |
q | Separation → Fig. |
q | Location → Fig. |
15 - | Syncromesh ring 4th gear |
q | Checking for wear → Fig. |
16 - | 4th gear |
17 - | Needle bearing |
q | Lubricate before fitting |
18 - | Stop washer |
19 - | Roller bearings |
q | Can be removed without tools |
20 - | Shim |
q | For the input shaft |
q | Determine thickness → Chapter |
21 - | Outer track, roller bearing |
q | Remove → Fig. |
q | Fitting → Fig. |
22 - | Clutch housing |
23 - | Spring |
q | Fitting position → Fig. |
24 - | Locking keys |
25 - | Sliding sleeve |
26 - | Syncromesh hub |
q | Identiifcation and assembly of hub → Fig. |
27 - | Spring |
q | Fitting position → Fig. |
Note!
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Note!
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Note!
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Syncromesh ring | Measurement “a” on a new syncromesh | Wear limit |
3rd and 4th gears | 1.1 to 1.7 mm | 0.5 mm |
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