DIY ADS gearbox repair

Many owners of domestic cars often encounter malfunctions in the gearbox of the UAZ. But a Russian person is built in such a way that he always prefers to postpone repairs until later. As a result, the UAZ gearshift lever often starts to junk.

From the transmission, the rumble of gears is constantly heard, and sometimes the box stops responding altogether. It's time to start repairing it or replacing it with a better one, for example, the ADS checkpoint or the Daimos checkpoint.

The Russian organization Avtodetal-Service (ADS) specializes in the production of gearboxes for UAZ vehicles. The 5-speed gearbox "ADS Expert" is supplied to the Ulyanovsk Automobile Plant, where it is equipped with current models of domestic off-road vehicles. It is a one-piece crankcase and is synchronized in all forward gears.

The gearbox is equipped with both a spur and helical transfer case. Modern boxes "ADS Expert" have the following features.

1. By increasing the length of the gear change lever, the gearbox mechanisms function more smoothly.
2. The redesigned transfer case rod is equipped with a handbrake return spring mounting bracket, making it much easier to assemble the gearbox during installation.
3. The general gearbox layout and the selective gear changer have changed somewhat. This made it possible to prevent oil leakage and protect the gearbox sheathing from the penetration of earth and water.
4. A special sensor is mounted in the design, which provides uninterrupted power supply to the rear lights.
5. The filler opening of the transmission chamber is 2 cm lower. This is done to improve the circulation of oil inside the gearbox. Its getting into the transfer case is completely excluded.

In addition to ADS Expert, an improved version of the gearbox from Daimos, based on electric control, was developed for UAZ Patriot in 2013. This made it possible to completely eliminate the use of the RCP lever. A special washer is built in instead. The rear propeller shaft has also changed: it was shortened and the intermediate support was removed.

5-speed gearbox "Daimos" is also suitable for other UAZ models, including Simbir, Hunter and UAZ-3160.

To install a gearbox of a new model on the UAZ Hunter, it will be necessary to change the floor hatches of the car body to more modern ones. The other 2 car models will require a little modernization, since it is necessary to cut a hole in the floor for the gearshift lever.

During the installation work, qualified assistance will be needed, therefore it is recommended to entrust the replacement of the gearbox to a licensed service station.

If you want to replace some parts of the gearbox yourself, use the instructions for complete disassembly and assembly of the gearbox for UAZ. In this case, the repair can be carried out without the use of a lift and outside assistance.

Dismantling the UAZ gearbox will require the following tools and materials:

• a set of open-end and socket wrenches from 10 to 36;
• a special wrench for tightening the flat nuts (you can use a bicycle one);
• a set of Phillips and flathead screwdrivers;
• service wrench with straight and curved end (pliers);
• copper synchronizer or rod for working with gears;
• a small piece of metal pipe for holding keys when tightening nuts in hard-to-reach places;
• core chisel and heavy hammer;
• a set of gaskets for the UAZ gearbox;
• quality sealant that will be used to install the gaskets.

When choosing a set of keys, it is important that they are as compact and thin as possible.Most fasteners are in an awkward position for dismantling, so choosing the right keys will save you time and hassle.

It is advisable to take gaskets for the current model, but if your car is of an old model, for example, with a UAZ 3303 gearbox, any set for the previous generation of cars will do.

If there is a need to update the gearbox, you will need to buy special sets of hardware for the gearbox and transfer case. The second set can be problematic as it is not easy to find in auto parts stores.

The scheme of the UAZ gearbox has its own peculiarities of connecting the transfer case and the gearbox. Of course, this type of construction provides a huge advantage, but it is difficult to remove it yourself, since the unit weighs about 80 kg. Without outside help, you will have to lift the car with a hand winch. In this case, you need to make sure that she has reliable support. For example, a metal frame or a sturdy beamed ceiling. The structure must be able to easily support the weight of your vehicle.

Before starting work, place the machine on a level surface. Then it is necessary to drain the oil from the gearbox and transfer case. Despite the common feeding system, each has separate drain plugs. While the grease flows out, you can dismantle the front seats, the dashboard and 2 hatches, which are located at the bottom of the body. After the oil has drained to the end, you need to put the plugs back in place.

Begin by unscrewing the frame crossbar, which is located under the handbrake system. Dismantle the front universal joint by disconnecting it from the transfer case flanges. Disconnecting the front axle couplings will help facilitate this process. The rear universal joint must be removed from the upper side of the body.

Next, you need to disconnect the exhaust pipe from the transfer case. In this case, it is necessary to loosen the fastening of the clamp on the pipe, otherwise it will interfere.

The clutch system must be dismantled, you should start by unscrewing the fasteners of the input shaft splines, while the hose is pushed into the bell. Loosen the 4 bolts that hold the clutch fork trim and remove the spring. Then unscrew the function cylinder controller and remove the plug.

The transfer case and gearbox will need to be well wrapped with a cable or rope and left for a while. Unscrew the pillow mounts and hardware holding the gearbox on the bell. This is done gradually and evenly. You can completely unscrew the bolts and nuts only if the box has moved slightly away from the bell. It is recommended to make temporary support for the machine motor with a jack, otherwise its lower part will hang and interfere. After successfully disconnecting the transmission, you can remove it completely.

It is best to replace worn parts inside the bell with new ones. This is especially true for studs, as their threads grind off very quickly.

Where to start dismantling the checkpoint

Dismantle the handbrake lever so that it does not interfere. After that, unwind the hardware connecting the checkpoint and the transfer case. Most often, this cannot be done in one motion, since the parts are held together with a sealant. We'll have to hit the knot well to sever them. It is very important to keep an eye on the spare parts, after disconnecting nothing should be lost. It is advisable to place them in one container and set aside until assembly.

The transmission and transfer case should be inspected for worn parts. To disassemble these parts, you need to try hard, since the bolts and nuts are in hard-to-reach places.

The input shaft has a roller bearing that has no cage, so in most cases it crumbles when dismantled. After assembling it, you need to pay attention to how the last video is placed. If the roller enters easily, it will have to be replaced, as this indicates wear on the part.

First you need to glue the gaskets to the gearbox and transfer case with a sealant. After that, the bracket is attached to the frame.

The handbrake system is installed back to the transfer case. For convenience, you need to hold the gear and lower the gearbox to its place through the hatch in the floor. Before this, you need to make sure that all the elements that were folded into a separate container are installed in their positions. Tighten the fastening hardware and put on the transmission cover. Now you need to check the functionality of the checkpoint. All gears should be shifted effortlessly, the absence of excess noise is important.

It is necessary to replace the release bearing with a new one, as this part wears out quickly. Dismantle the levers and hang the transmission with a secure cable. The finished release bearing is put on the gearbox, after which the spring is installed.

We proceed to one of the most difficult stages. It is necessary to insert the input shaft into the clutch system. It is quite difficult to do it yourself, but it is quite possible. You will need to try a little and move the gearbox in different directions, and do the same with the engine using a jack. Sooner or later, it will fall into place, but do not rush to push it close. First, insert the nut growers into the right hole. Then pull the transmission to the engine and secure the pillows.

Proceed with the installation of the clutch yoke and spline housing from the input shaft. This should be done in the same way as during dismantling, but in the reverse order. There are no special tricks here, difficulties will not arise.

Install the dashboard, parking brake and driveshafts using the same principle. It is recommended to replace the gimbal mount with a stronger one. In auto parts stores, you can buy hardened bolts, which are indicated by an English letter X on the cap. Avoid locally made bindings as they are rarely of high quality.

Refit the frame bar, attach the exhaust pipe bracket to the transfer case and adjust the parking brake. Refill with oil, close the sunroof and install the seats. Good luck!

About the book: ADS EXPERT gearbox manual for UAZ. 2007 edition.
Book format: pdf file in zip archive
Pages: 19
Language : Russian
The size : 6.9 mb
Download: free, no restrictions and passwords

Manual for the five-speed gearbox ADS EXPERT for UAZ, installation, malfunctions and their elimination.

Five-speed gearbox ADS EXPERT, manufactured by OJSC Avtodetal-Service, mechanical, synchronized in all forward gears, in one-piece crankcase 420.3181-1700010-02 or 420.3182-1700010. The gearshift scheme is classic.

Gearbox 420.3181-1700010-02 is intended for installation on cars of the family UAZ-3160, UAZ-3162 Simbir, UAZ Hunter with gasoline engines ZMZ-409, UMZ-4218 and diesel engines ZMZ-514 and Andoria.

Gearbox 420.3182-1700010 is intended for installation on cars of the cargo-passenger family UAZ-3741, UAZ-3962, UAZ-3303, UAZ-2206, UAZ-3909 with gasoline engines UMZ-4178, UMZ-4218, UMZ-4213, ZMZ-409.

In order to increase the resource indicators of the five-speed ADS EXPERT gearbox, its modernization was carried out:

1. Increased the length of the gear lever in the gearbox mechanism. The design of the cam for returning the lever to the neutral position has been changed, which made gear shifting clearer and easier, and eliminated the possibility of self-switching of the forward and reverse gears.

2. The pin for the transfer case has been improved, the parking brake return spring mounting bracket has been additionally installed, and the design of the housing of the eyelet of the rear end of the transmission has been changed, which has increased the convenience and saved time when installing and assembling the gearbox with the transfer case.

3.The design of the selective gear shifting mechanism was changed, an additional rubber seal for the lever was introduced, which made it possible to eliminate the likelihood of transmission oil leakage from under the lever. The properties of the rubber from which the boot is made were improved, this provided complete protection of the gearbox mechanism from dust and dirt and significantly increased the resource of the boot, and as a result, its reliability.

4. A reinforced design reverse gear sensor is installed with protection against aggressive environments, this ensures its uninterrupted operation.

5. Moved 20 mm below the filler hole in the gearbox housing, installed an oil deflector for the secondary shaft bearing, thereby ensuring better oil circulation in the unit and excluding spontaneous pumping of oil from the gearbox to the transfer case.

In addition to the above improvements, the five-speed ADS EXPERT gearbox has a number of consumer advantages:

- Extended range of speeds.
- Reducing fuel consumption by up to 20%.
- Installation of the gearbox is possible with both a spur and helical transfer case.
- Reduction of noise level during operation of the gearbox up to 80 dB.
- Easy and precise gear shifting.
- Wide range of installation kits.

1. General information about transmissions 420.3181-1700010-02 and 420.3182-1700010

2. Operational, technical characteristics of gearboxes 420.3181-1700010-02, 420.3182-1700010

3. Disassembly of gearboxes 420.3181-1700010-02, 420.3182-1700010

3.1. Removing the input shaft
3.2. Removing the output shaft
3.3. Removing the intermediate shaft

4. Malfunctions and their elimination

5. Assembly of gearboxes 420.3181-1700010-02, 420.3182-1700010

6. Instructions for installing gearboxes 420.3181-1700010-02, 420.3182-1700010 on UAZ vehicles

6.1. Instructions for installing gearbox 420.3181-1700010-02 on UAZ-3160, UAZ-3162 Simbir, UAZ Hunter cars
6.2. Instructions for installing gearbox 420.3182-1700010 on UAZ-3741, UAZ-3962, UAZ-3303, UAZ-2206, UAZ-3909 vehicles

7.Installation kits for gearboxes 420.3182-1700010 produced by JSC Avtodetal-Service

8. Parts for the repair of five-speed gearboxes manufactured by JSC Avtodetal-Service

9. List of gearbox wear parts

The main defects of the gearbox are:

• wear of gear teeth;
• breakage or chipping of teeth;
• wear of splines of shafts and gears;
• wear of bearings and places of their landing;
• wear of forks, stoppers and locks;
• crankcase cracks.

Elimination of individual defects of the gearbox is associated with its partial or complete disassembly. During disassembly, the following basic operations are performed:

1. disconnect the compressor (if any) from the gearbox housing;
2. remove the top cover with the gearshift mechanism;
3. unscrew the bolts, remove the front cover and remove the drive shaft with the bearing;
4. unscrew the back cover and remove the driven shaft with the bearing;
5. removed from the case of the gearbox of the driven shaft, the axle and the reverse gear;
6. remove the locking plate of the reverse axle and the intermediate shaft axle and knock out the axles (for ZIS-5 and ZIS-150 cars, unscrew the intermediate shaft bearing caps);
7. remove the reverse gear and the intermediate shaft or gear block from the crankcase.

Gear teeth are subject to normal wear due to friction and accelerated wear from improper shock shifting, incomplete tooth engagement, jerking, or poor lubrication. In this case, the teeth are chipped, chipped, and sometimes even broken.

The condition of the teeth is controlled by external examination, a template or by measuring their thickness with a caliper along the initial circle of the gear.

The teeth of the gears, which have burrs and a small working out, are cleaned with abrasive bars (donkey). Gears with chipped or broken teeth are replaced with new ones. To obtain the correct meshing of the teeth, it is necessary to replace the mating gears (pair) at the same time. Replacing one gear is allowed when setting not a new one, but an already working gear, which, although due to its wear, can be allowed for further operation.

If necessary, worn and chipped teeth can be restored by metal surfacing followed by heat and mechanical treatment.Gas welding of the teeth is performed with sormite No. 2 (hard alloy) or rods made of rejected connecting rod bolts and valve springs.

Rice. Installation of gears when surfacing teeth:
a - when surfacing the end surface; b - when surfacing the side surface.

When surfacing the end surface of the teeth, the following operations are performed:

1. Install the gear in a bath of water so that the teeth are immersed in water for 1 / 3-1 / 2 of their length (Fig. A).
2. The surface of the tooth is heated with an acetylene-oxygen torch until it sweats (without bringing the metal to melting), a flux (borax) is applied and sormite is applied with drops until the worn-out part of the tooth is filled. After surfacing all worn surfaces, the gear is left in the bath until it cools. When surfacing with rods from connecting rod bolts and valve springs, the teeth are hardened by lowering the gear into the bath. The weld-on teeth are cleaned with an abrasive bar.
3. When surfacing the lateral surface of the teeth, the gear is placed in a bath with water on the rod vertically (Fig. B) and the second tooth is deposited, counting from the surface of the water. When the fused tooth has cooled to a cherry color, it is immersed in water by turning the gear, then the next tooth is fused, etc.

At the end of the surfacing of all teeth, they are cleaned. Worn gear splines are rarely repaired, since gears are usually rejected earlier due to tooth wear. The slots can also be repaired by metal surfacing. Worn splines on shafts are sometimes restored by expansion followed by machining. In addition to wear on the splines, gearbox shafts can have bent and worn ball and roller bearing seats.

The shaft is checked for runout with an indicator at the centers of the lathe.

The bent shaft is straightened without heating under a press.

Worn bearing seats on shafts are restored by metal surfacing by welding, chrome plating, metallization or turning the journals, followed by pressing steel bushings.

Defects of parts of the gearshift mechanism are:

• bent or worn forks;
• wear of sliders;
• wear of locks and stoppers;
• wear of the gear lever.

These defects cause spontaneous disengagement of gears, simultaneous engagement of two gears, incomplete engagement of the gears and the release of the lever from the socket of the forks.

When disassembling the gearshift mechanism, you must:

1. unpin and unscrew the forks fastening bolts;
2. remove the slider of the first and second gears, as well as the lock and stopper (the rest of the sliders must be in the neutral position);
3. remove the reverse slider, stopper and lock;
4. remove the slider of the third and fourth gears and its stopper;
5. unscrew the cap or the locking bolt of the cover and remove the lever with the spring up (GAZ-51 car) or down (ZIS-150 car).

The deflection of the fork is determined on a test plate and is adjusted cold under pressure. After straightening and a second check, the fork is carefully inspected and, if cracks are found, replaced with a new one.

Worn fork cheeks (covering the gear carriage) and the socket for the ball end of the gear lever are restored by welding the metal. The welded places are processed on a milling machine.

Worn out grooves on the sliders for stoppers and locks are corrected with an abrasive bar. In this case, it is necessary to ensure that the center of the recess is not displaced.

Worn balls of stoppers and locks, as well as weakened springs, are replaced.

Rice. Gearbox of the GAZ-51 car:
1 - spacer sleeve; 2 and 6 - cylindrical roller bearing; 3 - the axis of the gear block; 4 - drive shaft; 5 - drive shaft bearing cover; 7 - back cover of the driven shaft; 3 - driven shaft; 9 - flange; 10 - speedometer gear; 11 - ball bearing; 12 - lock plate; 13 - carriage with reverse gears.

When assembling a four-speed gearbox (GAZ-51 car), you must:

1. lower the carriage with reverse gears 13 into the box crankcase and insert its axis;
2. install a cylindrical roller bearing 2, a spacer sleeve 1 and a second cylindrical roller bearing into the gear block;
3. lower the gear block into the crankcase, skip the axle 3 of the gear block and secure it with the locking plate 12 together with the reverse axis;
4. press the ball bearing onto the drive shaft 4 and secure it with a retaining ring;
5. insert the bearing thrust ring into the housing of the crankcase and install the drive shaft;
6. put on the drive shaft bearing cover 5 with a gasket and bolt it to the crankcase;
7. install a cylindrical roller bearing 6 into the groove of the drive shaft and insert the driven shaft 8, on the front end of which put a thrust ring, and on the rear end - a thrust ring, oil deflector, ball bearing 11 and speedometer gear 10; when installing the driven shaft, you should simultaneously put on carriages with gears of the first and second, third and fourth gears on it;
8. install the gasket and screw on the rear cover 7 of the driven shaft;
9. assemble the gearshift mechanism (in the reverse order of disassembly), install the cover with the gasket on the crankcase, inserting the forks into the corresponding gear carriages, and bolt it to the crankcase.

Rice. Gearbox of the car ZIS-150:
1 - power take-off gear hatch; 2 and 7 - nuts; 3 - thrust washer; 4 and 6 - lock washers; 5 - power take-off gear; 8 - a gear wheel of the fourth transfer; 9 - clutch for easy engagement of the fourth and fifth gears; 10 - a gear wheel of the fifth transfer; 11 - a gear wheel of the third transfer; 12 - gear wheel of the second gear with internal teeth for the third gear; 13 - gear wheel of the first transfer and reverse; 14 - thrust ring of the ball bearing; 15 - speedometer gear; 16 - cylindrical roller bearings; 17 - reverse gear block; 18 - hatch of the reverse gear block.

When assembling a five-speed gearbox of a ZIS-150 car, you must:

After the parts have been repaired and the gearbox is assembled, it is run in at the bench for running-in parts and to determine the ease of gear shifting, the absence of noise, knocking, heating and oil leakage.

The running order is as follows:

1. The gearbox is installed on the stand, the drive shaft is given 1200-1500 rpm and gears are changed, working in each gear for 2-3 minutes.
2. Pour oil into the gearbox housing to a normal level and check the operation of the gearbox in all gears with a load for 30-40 minutes.
3. After eliminating the identified defects, replace the grease and flush the crankcase with kerosene.

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UAZ cars (loaf) have the most capacious body. The body of the machine is made of durable material. The vehicle is equipped with security systems, a robust power unit capable of developing more than 100 horsepower, and a transmission system.

The all-wheel drive passenger-and-freight UAZ, which has increased cross-country ability, began to be mass-produced at the Ulyanovsk Automobile Plant in the mid-1960s.

On the machines of the UAZ - 452 family of the new model, there is a manual transmission (four-speed). Synchronizers of the inertial type provide easy shifting of gears. The five-speed ADS gearbox is synchronized in all forward gears.

A 5-speed manual transmission Daimos (DYMOS) can be installed on the UAZ. This transmission is distinguished by its reliability. The average resource of its work is 300,000 km of run. The filler plug is located in the middle of the box, the drain is at the bottom. It seems possible to unscrew them with a hex wrench. When the oil is drained, a special container should be prepared.New fluid must be filled up to the level of the oil filler hole on the box. The dipstick allows you to accurately determine to what mark the liquid is poured. An alternative to the stylus is a long nail. For preventive purposes, it is necessary to measure the oil level every 15,000 km.