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Leon Mk1

General repair instructions
General repair instructions
Edition 06.2011
Extremely careful way of working as well as the highest possible cleanliness are necessary to ensure the trouble free repairing of the gearbox. Furthermore, the tools must be in perfect condition. Obviously, the basic rules for safety also apply during repair work.
A number of generally applicable instructions for the various repair procedures which were previously repeated at numerous places in the workshop manual are summarised here. They apply for this individual Workshop Manual.
Contact corrosion
t  The gearbox housing and clutch housing are made of a magnesium alloy.
t  Bolts and other components in direct contact with the gearbox have a surface matched to it.
t  If the incorrect components (bolts, nuts, washers and so on) are used, contact corrosion will develop. The gearbox housing and clutch housing will be damaged.
t  Always install parts listed in the → Electronic parts catalogue „ETKA“.
Special tools
For a complete list of special tools used in this Workshop Manual → Workshop equipment and special tools.
Gearbox:
t  When installing, ensure that the dowel sleeves between the engine and gearbox are correctly located.
t  When installing mounting brackets or waxed components, clean the contact surfaces. The contact surfaces must be free of wax and grease.
t  Allocate bolts and other components using → Electronic parts catalogue „ETKA“.
t  After installing, check oil level → Chapter.
t  Capacity, 2.3 l
Gaskets, seals
t  Renew seals and gaskets.
t  After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage.
   
t  Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease -G 052 128 A1-.
t  The open side of the oil seals faces toward the side with fluid filling.
t  Following installation, check gear oil level → Chapter.
t  Lightly lubricate O-rings before installation to prevent them from being trapped and damaged during assembly.
Sealant
t  Thoroughly clean housing joint surfaces before applying sealing paste.
t  Apply sealing paste -AMV 188 200 03- evenly and not too thickly.
t  Breather holes must remain free of sealing paste.
  N32-0001
Safety locks
t  Renew retaining rings.
t  Do not overstretch retaining rings.
t  Retaining rings must locate properly in grooves.
t  Replace the support sleeves. Installation position: the groove must face parallel to the direction in which force is transferred.
Bolts, nuts
t  Loosen and tighten bolts and nuts for covers and housings diagonally.
t  Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in diagonal sequence.
t  Specified torques given are for unlubricated nuts, bolts and screws.
t  Always renew self-locking nuts and bolts.
t  Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.
t  Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a danger of the bolts shearing off the next time they are removed.
t  Check pitch of thread, to ensure correct thread chaser is used to clean threads and to ensure the threads are not damaged.
Antifriction bearings
t  Install new tapered roller bearings as supplied; do not lubricate additionally with oil.
t  Install needle bearings with lettered side (thicker metal) towards fitting tool.
t  Conical roller bearings fitted into one same shaft must be replaced together. They must have the same manufacturer.
t  Use inductive heater -VAS 6414- to heat the inner races of the conical roller bearings to approx. 100°C before installing. Engage to stop without allowing axial clearance.
t  Do not interchange the outer and inner ring of a conical roller bearing with those of another with the same size. The bearings come in matched pairs.
Shims
t  Measure shims at several points with a micrometer. The various thicknesses make it possible to achieve the exact shim thickness required.
t  Check that it is not burred or damaged.
t  Only fit shims in perfect state.
Synchromesh rings
t  Do not interchange! When reusing synchro-rings, always fit to the same selector gear.
t  Check for wear and renew if necessary.
  A34-0149
t  Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).
t  Make sure that the coating of coated synchro-rings is not damaged.
t  If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for »scoring«, »signs of abnormal wear« and »blue discolouration (due to overheating)«.
t  Check the cone of the synchromeshed gear for »scoring« and »signs of abnormal wear«.
t  Lubricate synchro-rings with gear oil before installing.
Gear wheels
t  Before engaging the gear wheels, clean thoroughly and heat to max. 100 °C using the inductive heater -VAS 6414-.
mobile pinion
t  After assembly, check synchromeshed gears for slight play, or for freedom of movement.
Coupling unit
t  Ensure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in several gradual stages.
t  If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.
  N35-10107

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