seat Workshop Repair Guides

SEAT Workshop Service and Repair Manuals

ABOUT US
Clutch, control > < Calculation of the demultiplication ratio ?I?

Leon Mk1

General recommendations for gearbox repair
General recommendations for gearbox repair
For a perfect, successful repair in the gearbox, it is essential to maintain maximum cleanliness and take the utmost care, and also to use tools in optimal conditions. When undertaking repairs, observe the basic rules on safety.
There follows a series of general recommendations for certain repair operations, which otherwise would appear several times in a number of sections of this Repair Manual. These recommendations will therefore be valid and must be considered for this Repair Manual.
Gearbox
t  Before fitting the gearbox to the engine, make sure that the centring bushings between the engine and the gearbox are in a good state and seat properly.
t  If replacing the gearbox, fill with oil to the lower edge of the filling hole. Filling quantities and oil type → Chapter.
Joints
t  Always replace the o-rings.
t  Before applying sealant products (liquid joints), thoroughly clean the contact surfaces and apply -AMV 188 200 03- sealing paste.
Seals
   
t  Before fitting, lightly impregnate with gearbox oil on the outer diameter and fill the space between the sealing lips with grease.
t  With the seals in place, check the oil level in the gearbox and fill if necessary.
Locking elements
t  Always replace lock rings, taking care not to oversize them when fitting.
t  The lock rings must fit perfectly in the bottom of the fitting groove.
t  Always replace the elastic pins.
  N32-0001
t  When fitting the elastic pins, the groove must be positioned longitudinally with respect to the force trajectory, as shown in the figure.
Bolts, nuts
t  Always loosen and tighten the bolts and nuts in a cross when fitting covers and housings. With delicate parts, such as the clutch press for instance, do not incline them and proceed gradually.
t  The torques indicated refer to unoiled nuts and bolts.
t  Self-locking bolts and nuts must always be replaced.
Bearings
t  Needle bearings must be fitted with the thickest side towards the fitting shaft-tool.
t  All gearbox bearings must be fitted impregnated in gear oil. Take special care when oiling for friction torque measurements.
t  Bearings belonging to the same shaft must be replaced as a unit. Use brands by the same manufacturer as far as possible.
t  To fit bearings, they should first be heated to 100 ºC approximately. Use the -SAT 1416- electroblower and the digital thermometer -SAT 4002- to check the temperature.
t  Do not mix or exchange the exterior tracks of bearings of the same size; bearings come in pairs.
Adjustment washers
t  Before fitting the adjustment washers, their thickness must be checked by using a micrometer to measure the surface at various points.
t  The existence of washers with adjusted tolerances allows the required thickness of the washer to be known precisely.
t  Washers must have no burrs or be damaged in any way.
t  Only fit adjustment washers in a perfect condition.
Synchroniser rings
t  Do not mix the synchroniser rings of different gears. If they have to be reused, fit them to the same gear as before.
t  Check for wear and replace if necessary.
t  To fit, impregnate in gear oil.
Gearings
t  Before fitting, clean with the utmost care. Gears must first be heated to 100 ºC approximately. Use the -SAT 1416- electroblower and the digital thermometer -SAT 4002- to check the temperature.
  V34-1515

Clutch, control > < Calculation of the demultiplication ratio ?I?