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Torque converter > < Final drive

Leon Mk2

General notes
General notes
To achieve a perfect and successful repair of the gearbox, it is imperative to keep everything scrupulously clean and use the correct tools in perfect working order. When carrying out repairs bear in mind basic safety rules.
Here is a summary of general instructions for certain repair jobs, which would otherwise appear several times in the different sections of this Workshop Manual. Thus, these instructions must be taken into account for this Workshop Manual.
Gearbox
t  Before fitting the gearbox to the engine, make sure that the dowel pegs between both elements are in good condition and correctly seated.
t  Clean contact surfaces on fitting blocks, supports or waxed components. The surfaces must be completely free from wax or grease.
t  If the automatic gearbox has been replaced, check and top up with ATF if necessary. Filling amount and oil type specifications → Chapter
   
Oil seals
t  Before fitting the radial seals, fill the gap between the sealing lips with grease
t  Replace O-rings
t  After fitting, check the level of ATF liquid and refill if necessary
Sealant
t  Clean contact surfaces thoroughly and apply -D 176 404 A2- sealing paste
t  Check the use-by date of the sealant.
t  After applying the sealant, screw the parts in within 5 minutes
t  After fitting, the sealant should dry in approx. 30 minutes Then fill with ATF
Safety locks
t  Always renew the safety rings, taking care not to stretch them excessively when fitting
t  The safety rings must be perfectly seated in their groove.
  N32-0001
t  Renew all split pins
t  On fitting split pins, the expansion groove should be facing the direction of power transmission.
Bolts, nuts
t  Always loosen and tighten nuts and bolts on covers and casing in diagonal sequence.
t  When dealing with particularly delicate parts, such as the slide box, always loosen and tighten the bolts in a diagonal sequence, gradually and in stages.
t  Tightening torques for nuts and bolts not coated with oil are indicated.
t  Always replace any self-locking nuts and bolts.
t  Bolts with torque and stretch specifications must always be renewed.
t  Clean screw threads impregnated with locking paste using a wire brush. Then insert the screws with -AMV 185 100 A1-.
t  The bolts and nuts of all threaded joints will be waxed when fitted (if specified).
Bearings
t  Partially lubricate all the gearbox bearings with ATF before fitting.
t  Fit new roller bearings as supplied, without lubrication, especially the conical ones.
t  Fit axial needle bearings in the correct position.
t  Bearings corresponding to the same shaft will be all replaced together, especially if they are conical. If possible, use parts from the same manufacturer.
t  Do not mix up the inner and outer rings of the same size bearings. The bearings come in matched pairs.
t  Heat the inner roller bearing ring to 100 °C before press fitting.
Removal of outer rings of roller bearings and bearing bushes with tool set -T20140-
Remove the outer rings of the 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 correct clamp from the tool set according to:
If the diameter measured is less than 30 mm:
–  Fit the plunger for small clamps/10 and the correct clamp for internal diameters.
If the diameter measured is more than 30 mm:
–  Fit the plunger/28 and the claw /29 for the internal diameters.
–  Screw the nut /5 and washer on the plunger.
  V34-1515
–  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.
  Note!
The legs of bridge /1 have different-sized cut-outs -arrows- to facilitate the support on surfaces with different heights, edges or ribs.
–  Adjust the threaded legs of the bridge /1 so that the bridge is parallel to the surface of the casing.
–  Open the clamps until the bar is housed below the exterior roller bearing or the bearing bush.
–  Action the extractor until the outer ring of the roller bearing or bearing bush is extracted.
  Note!
Due to the fact that on some occasions the space for the claw is minimal, a first extraction should be carried out to remove the bush, and then open the claws as far as possible to ensure the maximum contact surface. Then continue with the extraction.
Piston ring
t  Do not overstretch when removing or fitting.
Shims
t  Before fitting shims, check thickness measuring several points of the surface with a micrometer.
t  The existence of different thicknesses allows the exact calibration of the thickness of the shim needed.
t  Check they have no lips and that they are not damaged. Only fit shims in perfect state.
Clutches and brakes
  E34-0392
t  Clutches K1, K2 and K3 must be dismantled for cleaning. Allocate defective parts (e.g. outer or inner disks) according to the gearbox codes
t  Before fitting the piston, dampen the sealing lips and seals with ATF
t  After fitting to clutches or brakes, it must be possible to easily turn the piston by hand in both directions -arrow-. If this is not the case, perhaps the sealing lips or seals are incorrectly fitted or damaged.
–  Should this problem arise, remove the piston.
–  Inspect for damage to the sealing lips or seals and change where necessary.
–  Re-fit the piston and check again.
Slide box
  N38-0127
t  If any control elements are burnt, the slide box must be replaced.
Inner disks
t  Before fitting the new inner disks, place them in ATF for 15 minutes
Self-diagnosis
t  Before repair work on the automatic gearbox, the possible cause of the damage must be determined as precisely as possible → VAS 5051; Vehicle self-diagnosis.
  N00-0390

Torque converter > < Final drive