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Dismantling and assembling output shaft > < Output shaft

Leon Mk2

Secondary shaft: Assembly overview
Secondary shaft: Assembly overview
  Note
t  Mount gearbox on assembly stand → Chapter.
t  Refer to → Electronics Spare parts catalogue (ETKA) and technical data when installing new gears or a new output shaft → Chapter.
t  Replace both conical roller bearings together.
t  Lubricate the bearings, mobile gears and synchromesh rings of the secondary shaft with gear oil.
t  Do not mix up synchromesh rings. If re-using, allocate them to corresponding mobile pinion.
   
1 - Conical hexagon bolt
q   25 Nm + 90°
q   4x
q   To secure the bearing housing
q   replace
2 - clutch housing
q   Repairing → Chapter
3 - Shim
q   For output shaft
q   Determining thickness → Chapter
4 - Small tapered roller bearing outer race
q   Removing → Fig.
q   Fitting → Fig.
5 - Small tapered roller bearing inner race
q   Removing → Fig.
q   Fitting → Fig.
6 - Output shaft
q   Paired with final drive gear wheel. Always renew as a set.
q   In case of replacement: → Chapter
q   Adjust convergence → Chapter
7 - Large tapered roller bearing inner race
q   Removing → Fig.
q   Fitting → Fig.
8 - Seal
q   4x
q   Always replace.
q   For the securing bolts of the bearing housing → Item
9 - Bearing housing
q   With large primary shaft bearing outer track → Item
q   The external track should only be replaced together with the large roller bearing and the bearing housing
10 - Thrust washer
q   Shoulder of thrust washer faces tapered roller bearing
11 - 1st speed selector gear
q   Before fitting the gear pinion of the 1st gear, install the thrust washer → Item
12 - Needle bearing
q   For the sliding 1st gear
13 - Synchro-ring for 1st gear
q   Inner ring for 1st gear
q   Installation position → Fig.
q   Check for wear → Fig.
q   Check that the tabs show no signs of wear
14 - Outer ring for 1st gear
q   Installation position → Fig.
q   Renew if scored
15 - Synchro-ring for 1st gear
q   Installation position → Fig.
q   Check for wear → Fig.
16 - Mobile element with synchromesh body of 1st and 2nd gear
q   Removing → Fig.
q   Dismantling → Fig.
q   Assemble the mobile element and synchromesh body → Fig.
q   Installation position → Fig.
q   Fitting → Fig.
17 - Circlip
q   Use pliers -A-81124- to remove the safety ring.
q   Always replace.
18 - Synchroniser ring for 2nd gear
q   Identification
q   Checking for wear → Fig.
q   Installation position: The grooves in the synchromesh ring must fit with the pins in the synchromesh assembly of 1st and 2nd gear → Item
19 - Outer ring of 2nd gear
q   Insert in synchro-ring → Item
q   Installation position → Fig.
q   Replace if it shows signs of wear or grooves
20 - Synchro-ring
q   Inner ring of 2nd gear
q   Checking for wear → Fig.
q   Check that the tabs show no signs of wear
q   Installation position → Fig.
21 - 2nd speed selector gear
q   Installation position → Fig.
22 - Needle bearing
q   For 2nd gear mobile pinion
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
q   Remove together with the 2nd gear mobile pinion → Fig.
q   Fitting → Fig.
25 - Needle bearing
q   for the 3rd gear selector gear
26 - 3rd speed selector gear
27 - Syncromesh ring 3rd gear
q   Identification
q   Checking for wear → Fig.
28 - Locking collar with synchro-hub for 3rd and 4th gears
q   Removing → Fig.
q   Dismantling → Fig.
q   Assemble the mobile element and synchromesh body → Fig.
q   Installation position, locking collar and synchro-hub → Fig.
q   Fitting → Fig.
29 - Needle bearing bush
q   Remove together with the synchromesh assembly of the 3rd and 4th gear → Item
q   Fitting → Fig.
30 - Needle bearing
q   For 4th gear mobile pinion
31 - Syncromesh ring for 4th gear
q   Identification
q   Checking for wear → Fig.
32 - 4th speed selector gear
33 - Thrust washer
34 - Needle bearing
q   For output shaft
q   removing and fitting → Chapter
35 - Gearbox
36 - Needle bearing bush
q   Removing → Chapter
q   Fitting → Chapter
37 - 5th gear mobile pinion
q   removing and fitting → Chapter
38 - Dished spring
q   Installation position: The concave side must show towards the 5th gear pinion
39 - Securing bolt of mobile pinion of 5th gear
q   80 Nm and retighten 90°
q   The screw head incorporates a housing for the plate spring → Item
q   Fitting → Chapter
q   replace

   

Dismantling and assembling output shaft > < Output shaft