DIY VAZ 2108 gearbox repair

We clean it from dirt and rinse the gearbox outside.

In the same way, remove the circlip from the secondary shaft bearing.

You can replace the hinge of the gear selector shaft on the gearbox installed on the vehicle. For clarity, we carry out this operation on the removed rod.

In the same way, we replace the outer bearing ring of the input shaft.

In the same way, we knock out the oil seal and the outer ring of the differential bearing from the gearbox housing. We take out the adjusting ring.
We clamp the input shaft in a vice with soft metal pads.

To disassemble the output shaft, we support the main gear drive gear on a wooden stand.
We insert a chisel or a powerful screwdriver into the gap between the end of the drive gear and the inner ring of the front bearing.

We clamp the secondary shaft in a vice with soft metal pads.

We clamp the driven gear of the final drive in a vice with soft jaws.

To remove the differential bearings, we clamp the box in a vice.

Remove dirt and wash the outside of the gearbox.

2. Place the transmission straight up.

3. Remove the six nuts securing the rear cover.

4. Remove the mounting bolt and.

5. ... remove the clutch cable bracket.

6. Gently hit the back cover with a rubber mallet.

Remove the gasket carefully, as an undamaged gasket can be re-installed during assembly.

7. Remove the rear cover from the Lada Samara gearbox housing.

8. Remove the gasket.

9. Engage 3rd or 4th gear.

10. Remove the 5th gear fork bolt and engage 5th gear.

To secure the shafts from turning, it is necessary to simultaneously engage the 5th gear and the 3rd or 4th gear. To engage 5th gear, move down the synchronizer clutch together with the fork (the fork fastening bolt must be unscrewed) so that the splines of the clutch mesh with the gear rim of the gear.

11. Make sure the shafts do not turn.

12. Loosen the nut on the output shaft.

13. Unscrew the nut on the output shaft.

The nuts on the shafts are tightened with a high torque, so you need to apply a lot of effort to loosen.

14. Unlock the nut on the input shaft.

15. Unscrew the nut on the input shaft.

Remove the synchronizer carefully. Make sure that the synchroniser sleeve does not come off the hub: the spring-loaded synchroniser locking balls may crumble.

16. Use screwdrivers to hook the 5th gear synchronizer of the VAZ 2109 onto the hub.

17. ... and remove it together with the plug. Remove the plug from the coupling.

18. Remove the 5th gear synchroniser locking ring.

19. Use a screwdriver to hook up the 5th gear driven gear.

20. ... and remove it from the secondary shaft of the samara fret.

21. Remove the needle bearing thrust washer.

22. Remove the 5th gear needle bearing.

23. Use a screwdriver to hook up the 5th gear drive gear.

24. ... and remove it from the input shaft.

25. Use an impact screwdriver to remove the four screws holding the bearing plate.

26... Remove the bearing plate.

27. Pick up with screwdrivers and remove the 5th gear needle bearing sleeve of the VAZ 21099 from the secondary shaft.

28. Remove the thrust washer from the pinion shaft.

29. Remove the input shaft bearing retaining ring. To do this, press the retaining ring against the bearing ring with one screwdriver, and remove the ring from the groove with the other screwdriver.

30. Remove the pinion shaft bearing retaining ring in the same way.

31. Unscrew the retainer cap.

32. Carefully remove the retainer ball with spring.Remove two more clips in the same way.

33. Remove the two mounting bolts and.

34. ... remove the rear support of the power unit VAZ 2109.

35. Unscrew the reverse lock plug. Tilt the box and remove the retainer ball with spring.

36. Remove the 12 nuts and the bolt securing the gearbox housing to the clutch housing.

37. Using a large screwdriver, carefully separate the clutch housing and the lada satellite.

There are three places between the crankcases where you can insert a screwdriver to avoid damaging the gasket. Insert a screwdriver into these slots one by one and gently wiggle until the crankcases separate.

38. Remove the transmission case.

39. Remove the bolt securing the 1st and 2nd shift forks.

40. Lift the rod and remove it together with the shift forks for 1st and 2nd gears.

41. Remove the 3rd and 4th shift fork mounting bolt.

42. Disengage the stem head from the lever.

43. ... and remove it together with the plug.

44. Turn the 5th gear fork rod of the VAZ 2108, removing its head from the lever. Remove the stem.

45. Remove the retaining ring.

46. Remove the reverse gear fork.

47. Remove the reverse gear with the axle.

48. Slightly shaking, remove the input and output shafts at the same time.

When both gearbox shafts are removed, the inner rings of the front bearings remain on the shafts.

49. Take out the driven gear wheel of the final drive together with the differential.

50. Remove the three bolts securing the gearshift mechanism.

51. Remove the gearshift mechanism.

52. Carefully remove the gasket.

Do not damage the gasket when removing. An undamaged gasket can be reused when assembling the gearbox.

53. Press the pinion shaft front bearing out of the clutch housing. To do this, you can use the puller foot or a similar tool.

Press out the front input shaft bearings and the oil seal only when replacing them or replacing the clutch housing.

54. Press out the oil seal to replace the input shaft front bearing.

It is impossible to press out the input shaft oil seal without damaging it. Therefore, when replacing the input shaft bearing, you will need a new oil seal.

55. Press the bearing into the crankcase by applying force to the outer ring of the bearing.

56. Remove the magnet from the clutch housing.

57. Unscrew the nut that secures the speedometer drive housing.

58. Hook up the housing with a screwdriver.

59. ... and remove the housing from the driven gear of the speedometer drive.

If, during operation, traces of oil leakage through the hole for the speedometer drive were noticed, replace the rubber O-ring on the drive housing.

60. Remove the driven gear with the speedometer drive shaft from the housing.

61. Push the O-ring out of the speedometer drive housing.

62. Unscrew the reverse light switch from the gearbox housing.

63. Slide the protective cover for the shift link joint from the flange on the transmission.

64. Remove the opposite edge of the protective boot from the hinge flange.

65. Remove the bolt securing the hinge to the stem.

66. ... and remove the joint from the stem.

67... Remove the protective cover from the stem.

68. Remove the bolt securing the lever to the shift rod inside the clutch housing.

69. Remove the lever and rod from the clutch housing.

70. If, during operation, traces of oil leakage were noticed through the hole in the clutch housing under the gear shift rod, replace the rod oil seal.

GENERAL INFORMATION
Before removing the gearbox, disconnect the wire from the “-” terminal of the storage battery, and also drain the oil from the gearbox.

It is recommended to remove the gearbox with two people.
PERFORMANCE ORDER

1. Unscrew the mounting bolts and remove the crankcase protection.

2. Remove the bolt and disconnect the ground wire from the clutch housing.

3. Loosen the nuts on the clutch cable end.

4. Remove the cable end from the clutch lever.

5. Disconnect the block with the wire from the terminal of the starter traction relay.

6. Unscrew the fastening nut and disconnect the wire from the contact bolt of the starter traction relay.

7... Unscrew the three nuts (the third on the other side of the starter) fastening and remove the starter.

8. Loosen the clamp and disconnect the shift drive rod from the hinge end

9. Unscrew the fastening nut and disconnect the cable from the speedometer drive.

10. Disconnect the block with the wire from the reversing light switch.

11. Loosen the nut fastening the brace to the suspension arm.

12. Unscrew the nut securing the brace to the bracket or three bolts securing the bracket to the body and spread the left and right braces to the sides.

13. Remove the cotter pin nut securing the ball joint of the steering link to the pivot arm.

14. Remove the tie rod ball joint retaining nut.

15. Using a puller, press the tie rod ball joint pin out of the strut pivot arm.

16. Remove the two bolts and disconnect the suspension arm ball joint from the steering knuckle

17. Press out the shank of one of the inner CV joints of the front wheel drive with a pry bar from the gearbox and take it to the side.

18. Insert a technological plug instead (for example, an old inner CV joint). Then disconnect the second CV joint.

19... Remove the three mounting bolts and remove the clutch housing shield.

20. Loosen the three bolts and nuts securing the clutch housing to the cylinder block.

21. Place suitable wooden support blocks on the fender flanges in the area of ​​the A-pillar supports and place an engine support block on them. The bar must only rest on the wing flanges!

22. Attach the engine to the lifting eye with a long bolt with a hook. You can also use sturdy rope or wire to do this. (For the convenience of photography, the hood is removed).

23. Remove the two nuts securing the rear support of the power unit to the body.

24. Unscrew the nut and remove the bolt of the left support of the power unit.

25. Unscrew the three nuts securing the left support of the power unit to the transmission and remove the support.

26. Finally, remove the three bolts and the nut (on the other side of the transmission). When removing the transmission, first move it horizontally away from the engine to disengage the input shaft from the clutch. Do not damage the clutch diaphragm spring petals when removing.

Repair of the VAZ-2109 gearbox includes the following steps:

1. Remove the checkpoint from the VAZ-2109. We clean it from dirt using diesel fuel and a rag.

2. We take out the oil level dipstick from the gearbox.

3. Install the gearbox clutch housing vertically by unscrewing bolts 1 and 2 nuts 3 securing the clutch cable bracket. Remove the clutch cable bracket 2 from the gearbox.

4. Unscrew the remaining 4 nuts securing the back cover.

6. Unscrew the 5th gear fork mounting bolt.

7. Fix the gearbox shafts from turning.

8. Unscrew the input shaft securing nut.

9. Unscrew the secondary shaft securing nut.

10. Remove the 5th gear gear together with the synchronizer and the fork from the secondary shaft.

11. Remove the thrust plate from the synchronizer and remove the fork from the groove of the coupling.

12. Remove the 5th gear from the synchronizer with ring 1.

13. Remove the bushing from the secondary shaft.

14. Remove the 5th gear from the input shaft.

15. Unscrew the four screws using an impact screwdriver and remove the thrust washer 2 from the output shaft.

16. Remove the retaining rings of the shaft bearings.

17. Unscrew the 3 retainer plugs and carefully remove the retainer balls.

18. Unscrew the reverse lock plug, remove the O-ring and remove the retainer spring.

19. Remove the retainer ball by tilting the box.

20. Unscrew the 12 nuts and the gearbox housing securing bolt.

21. Separate the gearbox housing from the clutch housing by inserting a screwdriver into the grooves

22. Remove the gearbox housing from the clutch housing.

23.We unscrew the bolts of the gear shift forks 1-2 and 3-4.

24. Raise the 1st-2nd gear shift rod, it will come out of support 3, then turn counterclockwise, its head 1 will come out of engagement with the locking bracket.

25. Turn the shift rod of the 3-4th gear and remove the rod with the fork.

26. We turn the 5th gear inclusion rod and remove the rod.

27. We take out the axis of the reverse gear.

28. Shift the reverse gear until it stops in the gear mechanism, turn it by 30–40 degrees and remove the intermediate gear.

29. We take out the primary and secondary shafts.

30. We take out the differential from the clutch housing.

31. We unscrew the 3 bolts of the gear mechanism and remove the gear mechanism.

32. Remove the magnet from the clutch housing.

33. Unscrew the fastening nut and remove the housing from the speedometer drive gear.

34. Unscrew the reverse switch from the gearbox housing.

35. Press out the secondary shaft bearing.

37. Press out the input shaft bearing.

38. Press the new front shaft bearings into the clutch housing.

39. We move the edge of the protective cover of the stem.

40. We unscrew the bolt of the gear lever, remove the lever and take out the gear rod.

41. Replace the torn protective cover of the stem hinge.

42. To replace the clutch, press out the oil seals.

43. Remove minor damage with sanding paper on the clutch housing and gearbox or replace.

44. Checking the bearing seats in the clutch housing and gearbox. If there is wear, then we replace the crankcases.

45. We check the roller bearings, replace them if damaged.

46. ​​We check the gear shift rods; if damaged, we replace them.

47. We check the seals of the axle shafts, if there is a defect, we replace the seals.

48. We check the input shaft oil seal and the rod oil seal in the gears, in case of defects we replace it.

49. We clean the magnet from the wear particles of the elements. If there is damage, replace the magnet.

50. We clean the clutch and gearbox housings from the old sealant. Putting the checkpoint in the reverse order.

51. Install the shafts in the clutch housing.

52. Liberally lubricate all rubbing elements with oil.

54. Do not forget to replace the magnet.

55. Before installing the gearbox housing on the clutch housing, apply sealant to them around the entire perimeter.

You can read more about clutch operation here.

We install the engine on the car and rejoice at the good dynamic characteristics after the repair of the VAZ-2109 gearbox.

After the box is removed from the car, you can start disassembling it. Dismantling the gearbox on a VAZ 21099 car is necessary to perform various repairs to replace the failed system elements. To carry out the work, prepare a standard set of tools and perform the following sequence of actions:

• We put the box in a vertical position and proceed to disassembly. First of all, we need to remove the back cover by unscrewing the six bolts of its fastening. Then we unscrew the bolt and remove the clutch cable bracket.

• By applying light blows to the lid with a hammer, remove it from the studs, and then remove the sealing gasket located between the lid and the box body.

• Engage the third or fourth gear, then unscrew the bolt securing the fifth gear shift fork and then engage it by moving the clutch so that the splines mesh with the gear.

• Now, when the gears mesh with each other and the shafts, as a result, do not turn, we unscrew the secondary shaft nut, having previously unlocked it. It is advisable to unscrew this nut and the subsequent ones using a socket head so as not to damage the edges.

• Next, unscrew the input shaft nut. Then, prying the fifth gear synchronizer with two flat screwdrivers, remove it together with the plug. The synchronizer itself must be removed carefully so that the clutch with spring-loaded balls does not come out and they do not crumble.

• Now we remove the synchronizer blocking ring and after it, prying it with two screwdrivers, remove the driven gear of the secondary shaft.

• A needle bearing will be located under the gear, it must be removed together with the thrust washer.

• Next, remove the fifth gear drive gear by gently prying it with a screwdriver.

• Using an impact screwdriver, unscrew the four screws securing the clamping plate of the shaft bearings and remove it.

• Remove the needle bearing sleeve and the thrust washer located under it from the secondary shaft.

• We also use screwdrivers to remove the retaining rings of the bearings of the primary and secondary shafts.

• There are three retainer plugs on the side of the case. Using a spanner wrench, unscrew them one by one and carefully remove the ball and spring.

• The rear engine support is attached to the gearbox with two bolts, we need to remove it by unscrewing the mounting bolts.

• Next to the reversing light switch, there is a reverse speed detent plug. We unscrew the cork and then slightly tilt the box, remove the spring and the ball from the hole.
• Unscrew the twelve nuts of the bolts securing the clutch housing to the box body.

• Now you can separate the crankcase. To do this, use a screwdriver, the end of which is inserted into special slots located at the junction of the crankcases in three places.
• Between them there will be a sealing gasket, which we remove and replace with a new one during subsequent assembly, since it is not suitable for reuse.

• Next, we need to remove the stock with the first and second gear shift forks. To do this, unscrew the bolt of its fastening and lift it slightly, remove it.

• In the same way, we unscrew the bolt securing the rod of the third and fourth gears and removing the lever from engagement with the head of the rod, remove it.
• We immediately remove the fifth gear shift fork.

• Using pliers, remove the retaining ring and remove the reverse gear fork.

• Remove the reverse gear. Then, with both hands, we simultaneously remove the secondary and primary shafts. Note that when removing the shafts, the bearing inner races remain on the shafts.

• Remove the driven main gear together with the differential. Then we unscrew the three bolts securing the gearshift mechanism and remove it.
• Remove the bearings of the input and output shafts. Use a suitable paddle to press out the pinion shaft bearing. To remove the input shaft bearing, the oil seal must first be pressed in.

• There is a magnet in the clutch housing, to collect metal shavings, pull it out and clean it.
• Disassemble the speedometer drive housing.
• Unscrew the reversing light switch from the housing.
• Disassemble and remove the shift joint.

This completes the repair work on the complete disassembly of the gearbox on the VAZ 21099 car. Make the necessary repairs, and then carry out the assembly in the reverse order, taking into account the following nuances.

VAZ 2109 and 21099 cars are equipped with four-speed and five-speed manual transmissions. All gears, except for the rear, are equipped with synchronizers. Also, the box is combined with differentials.

It is extremely important to monitor the serviceability of the checkpoint, and if signs of damage are found, immediately eliminate them. With your own hands or with the help of a car service - this is your personal decision.

The inner structure of the box

To understand the essence of the repair, disassembly and assembly of the gearbox, the first step is to get acquainted with its device. In the case of the VAZ 2109, the box device is as follows:

• A block of driving gears is located on the input shaft, which are in constant mesh with the driven gears of the gears when moving forward;
• The second shaft has driven gears with needle bearings. There is also a pair of synchronizers;
• The output shaft is created in conjunction with the main gear drive gear;
• The driven gear of the main gear is attached to the flange of the two-satellite differential box;
• Differential bearings are always mounted with an interference fit, which is adjusted by selecting rings of different thicknesses.

Repair of the gearbox largely depends on the nature and type of malfunction. There are several options for the breakdown of this unit, in each of which appropriate actions should be taken to eliminate them.

Malfunction

Possible reasons

What do we have to do

Gear shifting with difficulty

• The clutch is not fully squeezed out;
• The thrust, which controls the gearshift mechanism, is deformed;
• The integrity of the jet thrust has been compromised;
• The fastening of the hinge or rod, which selects the gear, is loose;
• The speed change drive is incorrectly adjusted;
• The plastic components of the gear shift actuator are broken

• Try to straighten the traction. If this is not possible, replace them;
• Tighten the fastening screws more tightly;
• Adjust the gearshift drive;
• Replace damaged components

There is a spontaneous shutdown of gears

• The ends of the synchronizer teeth on the gear and coupling are damaged or worn out;
• Cracks have appeared, the rubber on the rear supports has peeled off;
• Incorrectly adjusted the gearshift drive;
• The thrust guard has been tightened incorrectly, due to which the gear is not fully engaged

• Replace worn out, deformed elements;
• Correct the position of the casing (cover) of the traction;
• Adjust the drive

Transmissions turn on with noise, crackling

• The clutch is not completely disengaged;
• The blocking ring of the gear synchronizer is worn out.

There is an oil leak from the gearbox

• Worn input shaft seal; Worn stem
• speed selection;
• Breakage of the speedometer drive roller seal;
• The fastening of the cover on the gearbox or crankcase is loose;
• The sealant under the gearbox cover is damaged;
• The fastening of the closure of the drain hole is loose

• Replace gaskets, use new sealant and gaskets;
• Tighten all available fasteners;
• Check the condition of the drain plug

In most cases, problems with the gearbox are eliminated by dismantling and disassembling it. Do not take on such a job without having the proper skills and experience.

To dismantle the box, we recommend that you rely on the instructions, clearly follow the sequence and consolidate the skills with visual videos.

1. Disconnect the negative terminal from the battery, drain oil from the gearbox system.
2. Unscrew the bolts that hold the crankcase guard and remove it.
3. Disconnect the ground (wire) from the clutch housing.
4. At the end of the clutch cable, slightly loosen the tension on the nuts.
5. Remove the cable end from the clutch lever.
6. Disconnect the block from the traction relay.
7. Disconnect the wire going to the starter traction relay.
8. Dismantle the starter itself directly.
9. Disconnect the drive rod from the pivot end. We are talking about traction, which carries out gear changes.
10. Disconnect the cable from the vehicle speedometer drive.
11. Unscrew the tie rod ball joint.
12. Remove, press out the tie rod pivot pin from the strut pivot arm.
13. The shank of the inner CV joint of the front wheel drive should be squeezed out and taken to the side.
14. Disconnect the second CV joint.
15. Remove the clutch cover.
16. Release the gearbox from the fasteners holding it to the engine.
17. Remove the box.

Be sure to move the box horizontally away from the motor before directly removing the box. Then disengage the input shaft. Be careful not to damage the clutch spring petals.