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Clutch, control > < 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.
Gearbox
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, Code letters, group numbers, ratios, filling quantities.
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 -arrow-.
t  Once the oilseals are fitted, check the oil level and top up if necessary.
Safety locks
t  Renew all safety rings, taking care not to stretch them excessively when fitting.
t  The safety rings 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 casings 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  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.
Removal of outer rings of roller bearings and bearing bushes with tool set -T20140-
Remove the outer rings of the roller bearings or the bearing bushes as follows:
–  Measure (if possible) the internal diameter of the external ring of the roller bearing or the bearing bush.
–  Select the correct clamp from the tool set according to:
If the diameter measured is less than 30 mm:
–  Fit the plunger for small clamps /10 and the correct clamp for internal diameters.
If the diameter measured is more than 30 mm:
–  Fit the plunger /28 with clamp /29 and the correct claws for the internal diameter.
–  Screw the nut /5 and washer on the plunger.
–  Place the tool on the outer ring of the roller bearing or the bearing bush and fit the threaded legs so that they are firmly secured.
  Note!
  V34-1515
The legs of bridge /1 have different-sized cut-outs -arrows- to facilitate the support on surfaces with different heights, edges or ribs.
–  Adjust the threaded legs of the bridge /1 so that the bridge is parallel to the surface of the casing.
–  Open the clamp until the bar is housed below the exterior roller bearing or the bearing bush.
–  Action the extractor until the outer ring of the roller bearing or bearing bush is extracted.
  Note!
Due to the fact that on some occasions the space for the claw is minimal, a first extraction should be carried out to remove the bush, and then open the claws as far as possible to ensure the maximum contact surface. Then continue with the extraction.
Oils
t  New gearbox code letters have been introduced, with a new mineral gear oil -API GL4 SAE 75W-. This type of oil must only be used in the specified gearboxes and never in those that used the former oil -API GL4 SAE 75W90- (synthetic oil).
t  Oils with different denominations and standards should never be mixed as this modifies the properties of the lubricant
  E34-0392

Clutch, control > < Calculation of the gear ratio ?i?