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 | 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 - | Gearbox casing |
2 - | Outer track, roller bearing |
q | Remove → Fig. |
q | Fit → Fig. |
3 - | Roller bearing |
q | Remove together with 1st gear → Fig. |
q | Fit → Fig. |
4 - | Stop washer |
5 - | Sliding 1st gear |
q | Installation position → Fig. |
6 - | Needle roller bearing |
q | For the sliding 1st gear |
7 - | Syncromesh ring |
q | Inner ring for 1st gear |
q | Checking for wear → Fig. |
q | Theck that the tabs show no signs of wear |
q | Installation position → Fig. |
8 - | Outer ring for 1st gear |
q | Fit it to the 1st gear syncromesh ring, item → Item |
q | Installation position → Fig. |
q | Replace if it shows signs of wear or grooves |
9 - | Syncromesh ring 1st gear |
q | Checking for wear → Fig. |
q | On fitting, the tabs on the ring must fit into their housings in the syncromesh assembly for 1st and 2nd gear → Item |
10 - | Circlip |
q | Separation → Fig. |
q | Location → Fig. |
11 - | Syncromesh assembly for 1st and 2nd gear |
q | They are matching pairs |
q | Remove → Fig. |
q | Assembly of components → Fig. und → Fig. |
q | Fit → Fig. |
12 - | Spring |
13 - | Sliding sleeve |
14 - | Syncromesh hub |
15 - | Locking keyways |
q | 3 units |
16 - | Spring |
17 - | Syncromesh ring 2nd gear |
q | Checking for wear → Fig. |
q | Installation position → Fig. |
18 - | Outer ring for 2nd gear |
q | Fit to syncromesh ring → Item |
q | Installation position → Fig. |
q | Replace if it shows signs of wear or grooves |
19 - | Syncromesh ring |
q | Inner ring for 2nd gear |
q | Checking for wear → Fig. |
q | Check that the tabs show no signs of wear |
q | Installation position → Fig. |
20 - | Sliding 2nd gear |
21 - | Safety ring |
q | Separation → Fig. |
q | Location → Fig. |
22 - | Needle roller bearing |
q | For sliding 2nd gear |
23 - | 3rd gear |
24 - | Circlip |
q | Separation → Fig. |
q | Location → Fig. |
25 - | Circlip |
q | Separation → Fig. |
q | Location → Fig. |
26 - | 4th gear |
q | Assembly position: the identification groove should face the cone |
27 - | Layshaft |
q | Check that the ratio (number of teeth) is correct → Chapter |
q | Adjusting → Chapter |
28 - | Roller bearing |
q | Remove → Fig. |
q | Fit → Fig. |
29 - | Outer track, roller bearing |
q | Remove → Fig. |
q | Fit → Fig. |
30 - | Shim |
q | For the layshaft |
q | Determine thickness → Chapter |
31 - | Clutch housing |
32 - | Stop washer |
q | The step of the shim should be facing the roller bearing |
33 - | Needle bearing bush |
q | Remove → Anchor |
q | Fit → Anchor |
34 - | Needle bearing for gear, 5th gear |
35 - | Sliding 5th gear |
36 - | Syncromesh ring 5th gear |
37 - | Spring |
q | Fit onto the 5th gear syncromesh ring |
q | Replace if it shows signs of wear |
38 - | Syncromesh hub 5th gear |
q | Removal, fitting and adjustment → Chapter |
39 - | Sliding sleeve 5th gear |
q | Removal, fitting and adjustment → Chapter |
40 - | Circlip |
Note!
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Note!
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Note!
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Ring syncromesh | Measurement “a” on a new syncromesh | Wearlimit |
1st and 2nd gears | 0.75...1.25 mm | 0.3 mm |
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Ring syncromesh | Measurement “a” on a new syncromesh | Wearlimit |
1st and 2nd gears | 1.2...1.8 mm | 0.5 mm |
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