The basic work of repairing a five-speed gearbox is similar to repairing a four-speed gearbox.
Disassembly and assembly of a four-speed gearbox is described in the article - "Disassembly and assembly gearboxes VAZ-2107”.
Five-speed transmissions since 1992 do not have a washer on the output shaft and the configuration of the output shaft and fifth gear synchronizer clutch hub has been changed.
On the secondary shaft, the diameter for the hub was 28, it became 25 mm; the width of the seat part of the hub has become larger and the seat diameter has been reduced from 28 to 25 mm.
The specified parts are not interchangeable with previously produced ones, therefore, when repairing an "old" design gearbox, we observe the following rules:
- - if the washer changes, then we put the secondary shaft and hub of the "old" design;
- - if instead of the secondary shaft or hub, the same-name parts of the “new” design are installed, then we change them as a set, that is, when replacing the hub, we also replace the secondary shaft and vice versa.
In this case, the washer is not installed.
To facilitate the removal and subsequent installation of the elastic coupling, wrap it tightly with tape.
You can clamp the elastic sleeve with a large band clamp
Having unscrewed three nuts with two “19” wrenches and removing three bolts, remove the coupling.
Remove the flexible coupling flange, gearbox support, speedometer drive.
Using the “10” key, unscrew the three nuts securing the ball joint of the gear lever
remove the lever from the studs of the rear cover of the gearbox
Using the “27” key, turn off the reversing light switch and remove it
Remove the bottom cover of the gearbox (see Disassembly and assembly of the gearbox VAZ-2107 ), and with the “13” key, unscrew the nut securing the rear cover to the gearbox housing
We unscrew the remaining nuts securing the rear cover to the gearbox housing
Use a screwdriver to press the first and second gear engagement rod
Remove the rear cover of the gearbox
Remove the rear output shaft bearing and its inner ring.
Remove the speedometer drive gear with a lock - a metal ball and remove the oil slinger.
Using the “10” key, we unscrew the bolt securing the third and fourth gear forks.
Turn on the third gear with a screwdriver.
Using the “17” key, we unscrew the bolt securing the gear block
Remove the gear block mounting bolt.
Remove the fifth gear and reverse gear
Remove the spacer.
Using the “13” key, we unscrew the two bolts securing the clamp cover and, having removed it,
- remove three springs and three balls of clamps.
Remove the fifth gear bushing.
Remove the fifth gear assembly with synchronizer
Having lifted the stem, remove the 5th gear synchronizer clutch
- and reverse intermediate gear.
Remove the fifth gear and reverse gear with fork.
Remove the fifth gear synchronizer clutch hub.
Further disassembly of the gearbox is carried out in the order described in the article - " Disassembly and assembly of the VAZ-2107 gearbox»
Assembly of the fifth stage, reverse gear and gear selection mechanism is carried out in the reverse order of disassembly, taking into account the following.
We fasten the axis of the intermediate reverse gear before installing the shafts in the gearbox housing with a torque of 78 Nm (8 kgf∙m).
Before installing the fifth gear and reverse fork rod into the crankcase, we install a distance sleeve on it.
We press the inner ring of the bearing onto the gear unit of the fifth gear and reverse gear, and the outer ring into the socket of the rear cover.
The rear bearing of the secondary shaft is pressed onto the shaft to facilitate the installation of the rear cover.
We install the reverse intermediate gear, the fifth gear driven gear and its fork at the same time.
We tighten the bolt for fastening the gear unit with a torque of 78 Nm (8 kgf∙m).
Permissible dimensions of gearbox wear parts
|
Mating parts |
Dimensions of mating parts |
Valid gap in conjugation, mm |
|
|---|---|---|---|
|
Hole |
Shaft |
||
|
Input shaft - front end output shaft plus two videos bearing |
25.328 +0.021 |
19.3 -0.020 -0.033+2(3 -0.006 ) |
25.40 - hole 19.25 - shaft |
|
Coupling hub synchronizer - output shaft |
38 +0.020 -0.020 |
38 -0.030 |
0.05 |
|
Driven gears III and II gears - output shaft |
43.5 +0.075 +0.050 |
43.5 -0.025 |
0.15 |
|
1st gear driven gear – driven gear bushing |
43.5 +0.075 +0.050 |
43.5 -0.025 |
0.15 |
|
Drive gear bushing I transfer - output shaft |
30 +0.030 +0.050 |
30.05 -0.016 |
0.016 |
|
Reverse driven gear - output shaft |
29.95 +0.030 |
29.95 -0.021 |
0.051 |
|
Intermediate gear Reverse with bushing - pinion axle |
20 +0.070 +0.050 |
20 -0.006 -0.021 |
0.15 |