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Drive shaft (drive pinion), disassembly and assembly > < Pinion shaft (output shaft)

Leon Mk1

Drive shaft (drive pinion): Assembly overview
   
Drive shaft (drive pinion): Assembly overview
  Note
t  Refer to technical data → Chapter when installing new gear wheels or the final drive gear set.
t  Lubricate all needle bearings on output shaft with gear oil before installing.
t  Adjustment work is required when renewing the parts marked with 1). Adjustment overview → Chapter.
1 - Gearbox housing 1)
q   Repairing → Chapter
2 - Shim „S3“
q   Adjustment overview → Chapter
3 - Tapered roller bearing outer race 1)
q   Remove → Fig.
q   Pressing in → Fig. and → Fig.
4 - Drive shaft (drive pinion) 1)
q   Is mated with crown wheel, always renew together as a set
q   Adjusting pinion shaft and crown wheel → Chapter
5 - Tapered roller bearing inner race 1)
q   breaks when removing
q   replace
q   Driving out → Fig.
q   Driving in → Fig.
6 - Circlip
q   Re-determine thickness if tapered roller bearing is renewed → Fig.
7 - Needle bearing
q   For 1st gear
8 - 1st speed selector gear
q   Check axial clearance after installing using feeler gauge → Fig. (0.20 ... 0.50 mm)
9 - Inner ring for 1st gear
q   Installation position → Fig.
q   Check for wear → Fig.
q   Renew if scored
10 - Intermediate ring for 1st gear
q   Installation position → Fig.
q   Check for wear → Fig.
11 - Synchro-ring for 1st gear
q   Installation position → Fig.
q   Check for wear → Fig.
q   Renew if scored
12 - Locking collar, 1st and 2nd gear
q   Mark position in relation to synchronising hub prior to removing
q   Assembling the mobile element/synchroniser body → Fig.
13 - Thrust blocks
q   Installing locking pieces (3x) → Fig.
14 - Synchronising hub for 1st and 2nd gear
q   Installation position: High inside collar faces 2nd gear wheel.
q   Driving out → Fig.
q   Driving in → Fig.
q   Assembling the mobile element/synchroniser body → Fig.
15 - Circlip
q   Mark
q   Installation position → Fig., -item 1-
q   Re-determine thickness when renewing 1st and 2nd gear synchronising hub or pinion shaft → Fig.
16 - Needle bearing
q   For 2nd gear
17 - Synchroniser ring for 2nd gear
q   Installation position → Fig.
q   Check for wear → Fig.
q   Renew if scored
18 - Intermediate ring for 2nd gear
q   Installation position → Fig.
q   Check for wear → Fig.
19 - Inner ring of 2nd gear
q   Installation position → Fig.
q   Check for wear → Fig.
q   Renew if scored
20 - Synchromeshed gear for 2nd gear
q   Check axial clearance after installing using feeler gauge → Fig. (0.20 ... 0.50 mm)
21 - Circlip
q   Mark
q   Installation position → Fig., -item 2-
22 - Tapered roller bearing inner race 1)
q   Driving out → Fig.
q   Driving in → Fig.
23 - Circlip
q   Mark
q   Installation position → Fig., -item 3-
24 - Thrust washer
q   For reverse gear shaft
q   Driving out → Fig.
q   Driving in → Fig.
25 - Tapered roller bearing outer race 1)
q   Remove → Fig.
q   Driving in → Fig.
26 - Shim „S4“
q   Adjustment overview → Chapter
27 - Bearing housing 1)
28 - Needle bearing
q   For reverse gear shaft
29 - Reverse gear mobile pinion
q   Check axial clearance after installing using feeler gauge (0.20 ... 0.50 mm)
30 - Spring
q   Insert into reverse selector gear → Fig.
q   Allocation of spring to selector gear → Spare parts catalogue
31 - Synchro-ring for reverse gear
q   Check for wear → Fig.
32 - Synchronizer body for the reverse gear
q   Installation position: High inside collar faces 3rd gear wheel.
33 - Reverse gear locking collar
q   Mark position in relation to synchronising hub prior to removing
q   Installation position: Taper faces reverse gear synchro-ring
34 - 3rd gear wheel
q   Installation position: Machined side faces reverse gear synchronising hub
35 - Circlip
q   Mark
q   Installation position → Fig., -item 4-
q   Re-determine thickness when renewing 3rd gear wheel, reverse gear synchronising hub or pinion shaft → Fig.
36 - Gear wheel for 4th gear
q   Installation position: High inside collar faces 5th gear wheel.
37 - 5th gear pinion
q   Installation position: High inside collar faces 4th gear wheel.
38 - Spacer bush
39 - Gear wheel for 6th gear
q   Installation position: High inside collar faces spacer sleeve → Item
40 - Circlip
q   Mark
q   Installation position → Fig., -item 5-
q   Re-determine thickness when renewing gear wheels for 4th ... 6th gear, the spacer sleeve or the pinion shaft → Fig.
41 - Needle bearing
q   Bearing for pinion shaft in gearbox cover
q   removing and fitting → Item
42 - Multi-point socket head bolt, 24 Nm
43 - Bracket
q   Secures needle bearing → Item in gearbox cover
44 - Gearbox cover

   
Inserting spring in selector gear
The bent end of the spring -arrow- must be hooked into the hole in the selector gear.
  V35-1036
Check the wear of the synchromesh ring
–  Press synchro-ring into locking collar and measure gap -a- at positions -A-, -B- and -C- using feeler gauge.
–  Add the measured values and divide by 3.
The determined value should not exceed 0.45 mm.
  V35-1037

Drive shaft (drive pinion), disassembly and assembly > < Pinion shaft (output shaft)