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

Leon Mk1

General repair instructions
General repair instructions
For proper repair of the gearbox, it is important to work with the greatest of care and absolute cleanliness, and to use tools that are in perfect condition. Naturally, the customary basic safety rules must be observed during repair work.
A series of general instructions for repair work is now listed, and these are mentioned several times throughout the course of the Repair Manual. These instructions are valid for this Repair Manual,
Contact corrosion
t  The gearbox casing is made of magnesium alloy.
t  The surfaces of the bolts and other parts which are in direct contact with the gearbox are made of a material which is especially suitable for the magnesium casing.
t  If inappropriate parts are used (bolts, nuts, washers...), corrosion will be produced through contact and the gearbox casing will be damaged.
t  If you are doubtful as to whether it is possible to re-use certain parts, it is advisable to fit new ones → Current parts catalogue.
  WARNING
t  Only use genuine Seat parts!
t  Damage from contact corrosion is not covered under the warranty!
Gearbox:
t  Thoroughly clean unions and adjacent areas before removing.
t  Select the correct bolts and other components → Parts catalogue.
t  When installing the manual gearbox, ensure that the dowel sleeves are correctly housed between engine and gearbox.
t  When installing support stands and waxed components, the contact surfaces must be cleaned. The contact surfaces must be free from wax and grease.
t  After replacing the gearbox, check oil level and top up if necessary.
t  Filling amounts and oil type specifications.
   
O-rings, seals, gaskets
t  O-rings, seals and gaskets must always be replaced.
t  After removing gaskets, check that the contact surfaces of the casing and shaft do not show feathering or damage caused by the removal process.
t  Before fitting radial seals, apply a little oil to their outer perimeters and fill the space between the sealing lips -arrow-, to half-way, with sealant grease → Parts catalogue.
t  The open side of the flanges must point towards the liquid to be sealed.
t  Fit the new flange in such a way that its sealing lip is not seated in the same place as the lip of the previous flange (taking advantage of the tolerance in the housing depth).
t  Before fitting O-rings, lightly lubricate them so that they are not flattened during installation.
t  Check oil level after replacing flanges and gaskets.
Sealant
t  Thoroughly clean contact surfaces of the casing before applying sealant to them.
t  Apply the sealing paste uniformly, in a layer which is not too thick → Parts catalogue.
t  Sealant must not enter the vent holes.
  N32-0001
Safety locks
t  Replace safety rings.
t  Do not over-expand safety rings.
t  The securing rings must be perfectly seated in their groove.
t  Replace split pins. Installation position: the groove -A- is positioned lengthwise to the flow of the pressure -arrow-.
Bolts, nuts
t  Loosen bolts and nuts in reverse of tightening sequence.
t  The bolts and nuts to be used to secure covers and casings must be released and tightened diagonally in stages when no tightening order is specified.
t  Always replace self-locking nuts and bolts.
t  The torque settings refer to non-oiled nuts and bolts.
t  Threaded holes where there had been self-locking bolts or bolts with thread fixing agent must first be cleaned (for example, with a threading male). If this is not done, the bolts may break when removed again.
t  In all bolted unions, ensure that supporting surfaces and bolts and nuts are only waxed after installation, if this is necessary.
Bearings
t  Install new roller bearings as supplied (without additional oiling).
t  All bearings (apart from roller bearings) of the gearbox must be fitted lubricated with gear oil.
t  Before fitting interior rings of roller bearings, first heat them to 100 ºC approx. Use the electric blower -SAT 1416-. When installing, they must be pressed in to their limit, without leaving axial play or rebound.
t  The temperature can be measured with the digital thermometer -SAT 4002-.
t  Do not confuse the outside and inside rings of the bearing with the rings from other bearings of the same size.
t  Roller bearings fitted into one same shaft must be replaced together, using products of the same manufacturer.
t  Position gear needle roller bearings with the stamped side (thicker plate) towards the mandrel to be fitted.
Shims
t  Check shim settings at various points, using a micrometer. The existence of different tolerances allows the necessary shim thickness to be selected exactly.
t  Check for burrs and damages. Install only perfect shims.
Synchromesh rings
t  Must not be swapped. Do not mix up synchroniser rings from different gears.
t  Check for wear and replace if necessary.
t  Fit them lubricated with gear oil.
Gears
t  Before fitting pinions, they must be cleaned and heated to 100 ºC approx. Use the electric blower -SAT 1416-.
t  The temperature can be measured with the digital thermometer -SAT 4002-.
mobile pinion
t  Check whether, after fitting, the mobile pinions of 1st ª to 6thª gear have slight axial play and move easily.
Clutch action
t  When removing the gearbox, the clutch slave cylinder must be extracted without opening the piping system.
t  If the clutch slave cylinder is removed together with the hydraulic pipe, do not press the clutch pedal. Otherwise, the slave cylinder piston will be expelled.
t  Do not incline the pressure disk; loosen slightly in each passage and diagonally, the installation is done in the same way.
t  To reduce the unpleasant smells of a burnt clutch, the clutch bell-housing must be thoroughly cleaned, along with the flywheel and engine at the side facing the clutch.
Extraction of the outer roller bearing rings and the bearing bushes using the kit -T20140-
l  Remove the outer rings of the conical 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 appropriate clamp from the kit -T20140- noting the following:
l  If the diameter measured is less than 30 mm:
–  Fit the valve tappet for small clips /10 and the appropriate clip for internal diameters.
l  If the diameter measured is greater than 30 mm:
–  Fit the valve tappet /28 with the clip /29 and the appropriate grips for internal diameters.
–  Screw nut /5 and washer onto the valve tappet.
–  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.
  A34-0149
l  The legs of the bridge /1 have different sized recesses -arrows- to support on surfaces of different levels, rims or ribs.
–  Adjust the screw feet of the bridge so that the bridge is parallel to the bearing allotment surface or bush and extract it.
–  Open the clamps until the bar is housed below the exterior roller bearing or the bearing bush.
–  Operate the extractor until the outer ring of the conical roller bearing or bearing bush is extracted.
  Note
In certain cases the space where the hooks must be fitted is minimum, an initial extraction must be carried out to partially remove the bearing bush, then, the hooks are re-adjusted the maximum possible to achieve a larger contact surface. Then, continue with the extraction of the bearing or the bush.
  E34-0392

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