DIY uaz loaf gearbox cover repair

In detail: do-it-yourself uaz loaf gearbox cover repair from a real master for the site my.housecope.com.

Dismantling the gearshift mechanism
SEQUENCING

Use a narrow slotted screwdriver to knock out the plugs of the gear shift rods.

Using the "17" key, unscrew the plug-plug of the retainer socket.

Using pliers, remove the safety wire of the bolts securing the forks to the rods ...

... and turn off the three bolts with a 10 key.

We knock out the fork rod of the 1st-2nd gear with a beard together with the plug.

We take out the plug and stem.
In order not to confuse the rods, we immediately put the forks on them and fix them with bolts.
Similarly, we knock out the fork rod of III-IV gears), ...

The blocker pin is located in the middle rod.
Knocking out the rod of the reverse gear fork, ...

... take out the ball with a spring.

Using the "10" key, unscrew the three bolts securing the fuse cover.

We take out the ball with a spring (fuse holder).

Sinking the ball with a slotted screwdriver, insert the stem into the hole in the cover.

We put a fork on the stem, tapping on the end of the stem with a soft metal hammer, ...

... and fix it with a locking bolt, aligning the holes in the stem and forks.

Install the plunger into the channel between the reverse gear fork and the III – IV gears.
Similarly, we install the III – IV gears rod with a fork and the second plunger (between the III – IV and I – II gears).
We install the rod of I – II gears, a fork, a ball with a spring and a retainer plug.
Clamping the switching mechanism in a vice and installing a lever on it, we check the correct assembly and operation of the mechanism. The rods should be easy to move and clearly fixed.
Counter bolts of gear shift forks with safety wire.

Video (click to play).

Orient the oil deflector washer with a protrusion to the inner ring of the bearing.

The bearings are pressed onto the shaft with a piece of pipe of a suitable length and corresponding diameter.
We carry out further assembly of the gearbox in the reverse order, while degreasing the gaskets and bolts of the crankcase covers and applying sealant to them.
We check the gear shift on the assembled box by turning its shafts by hand. Having installed the gearbox on the car and filled with oil, we check its operation in motion. Transmissions should turn on clearly, without jamming and noise. At the same time, make sure that the gears are fully engaged.

ATTENTION
The lever travel when engaging the first gear in a gearbox with synchronizers only in III-IV gears is 2.5 times greater than when engaging the second gear. Failure to engage the first gear causes rapid wear and destruction of the gears.

If you are the owner of a UAZ and there are suspicions about the failure of the gearbox, then you must definitely take on the repair. The unit fails when the driver has to hold the gearshift lever on the move, when they begin to shift by themselves (to prevent this, the drivers tie them up with ropes). Squeaks are sometimes heard.

To get acquainted with the repair technology, read about the repair of the UAZ 452 gearbox with your own hands. First, you need to determine the type of UAZ box that is on the car. Despite the difference between car models, the same transfer cases are installed on them. Therefore, we can assume that repairs are carried out in almost the same way. This will require a set of keys, some tools and aids (listed below).

On most car models of this type, both parts are one piece. The weight of such a unit reaches 75-82 kg, so you need an assistant.If the car being repaired has a safety cage, then you can use a hand winch to remove the UAZ 452 gearbox for repair on your own.

The car must be parked out of the blue, since later it will have to be moved 0.5 m forward or backward. First, drain the oil. Both boxes have a common volume, but the liquid drain plugs are separate. While the oil is pouring out, you need to remove the front seats and unscrew them, and then remove the halves of the hatch to the floor of the car. Next comes the turn of removing the speedometer rods.

When the oil has drained, screw the drain plugs back into place. There is a frame cross member under the hand brake drum, it must be removed. Disconnect the front axle clutches and unscrew the front universal joint. If you find weakness of the nuts on it, then you need to remove this part.

If the UAZ 3303 gearbox is being repaired, you need to be more careful with the couplings. The car is moved 0.5 m (in any direction) and the rear cardan is removed through the hatch. Disconnect the muffler from the distribution box and loosen the clamp on it. Then, one by one, details such as:

clutch pallet;
fasteners for the oiler from the input shaft (it is on the right, on the bell);
4 bolts that hold the clutch cover;
cylinder rod adjustment and fork.

The transfer box is wrapped with rope and hung. The following parts are removed:

pillow bolts;
nuts holding the bell box mount.

With these actions, the engine, when the UAZ 452 gearbox is repaired on its own, must be propped up with a jack. When the box is free, it is lowered and taken out from under the car. The levers must first be removed. The pins on the bell must be replaced with new ones.

If you need to repair the UAZ Patriot checkpoint, then it must be borne in mind that the location of the box and the bell is opposite there. This also applies to the position of the rods. But in general, the technology for repairing the UAZ 452 gearbox on its own is suitable for use.

Unscrew the bolts and nuts, disconnect the gearbox and its transfer case. A gasket reinforced with sealant is installed between them, so you will have to hit the bracket for attaching the assembly to the frame several times.

First you need to remove the input shaft cover and unscrew the left nut, which is located on it (see fig.). Now you need to remove its bearing. If it is out of order, it must be replaced. Its roller "brother" is installed inside the shaft, it also needs to be replaced. Then the circlip is removed from the secondary roll. Unscrew the double-row bearing stopper. The shaft must be knocked out and the part changed.

This is followed by the third gear clutch assembly. Copper synchronizers are replaced along with crackers. Then it is the turn of the reverse gear. Unscrew the intermediate shaft front bearing box. Do not hit it with a hammer or core: it is from silumin and may crack.

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Be careful not to damage its rubber pad as it is difficult to reach. On the removed shaft, replace the gears and all bearings. After that, assemble the box in the reverse order. When the roller is installed on the input shaft, it is abundantly lubricated with Litol. All units and parts are put in place one by one so as not to be mistaken.

Loosen the nuts of the flanges and shafts, remove them. The hand brake must be checked for operability, if necessary, it must be replaced. Remove all covers and replace the oil seals. Unscrew the drive of the speedometer rods and the breather (it must be replaced). The bearings are checked and replaced if necessary.

Transfer case assembly is done upside-down. These steps are repeated when working with other types of this car brand (including when repairing the UAZ Hunter gearbox). Install the fastener bracket to the frame. They put the transfer case on the parking brake drum and, holding the gear, lower it into place through the power take-off hatch.Before this, place a lock washer from the intermediate shaft. Tighten the bolts and nuts, put on the cover with levers and check the operation of all gears.They change the release bearing, remove the levers, drag the entire unit under the car and hang it on a rope. Slide the release bearing assembly onto the box and reinforce the spring. Then insert the input shaft and clutch. This is done as follows:

move the box up and down;

turn the engine by the flywheel;

put the knot in place;

fasten pillows.

Attach the oiler of the input shaft splines and the plug in place, put the speedometer drive, cardans, handbrake, covers in place. It is necessary to return the frame cross member to its place and fix the muffler bracket to the transfer case.Adjustment and adjustment of the hand brake, oil change are performed. If the UAZ Hunter checkpoint is being repaired, you may need not only these actions, but also the adjustment of the rods. Screw the hatch on the floor, put the seats. This completes the repair of the UAZ 452 checkpoint on its own. Image - DIY uaz loaf gearbox cover repair

To work you will need:

open-end wrenches from 10 to 22;
bearing puller;
screwdrivers (Phillips and flat);
platypuses (with curved noses and straight);
copper pin;
a piece of pipe as a handle for keys;
chisel and core;
hammer and assembly blade;
small cans for collecting nuts and screws;
socket wrenches 10 to 36;
lithol;
red sealant;
set of gaskets and retaining rings for the car.

In order to properly repair the UAZ 452 gearbox on your own, you must strictly adhere to the sequence of actions described above. Difficulties in repairing other models of this brand may be caused by a different arrangement of the main parts of the machine, for example, rods. The oil change must be carried out in accordance with the technical requirements for this type of vehicle.Do-it-yourself UAZ 469 checkpoint repair is a feasible task for a person who wants to save money. For other owners of UAZs (for example, UAZ loaf), all of the above can be taken into account and the UAZ gearbox can be repaired, taking into account some difference in details and the location of the rods.Assemble the gearshift mechanism for cars of the UAZ-31512 family in the following order: Install the rubber O-ring (Fig. 114) into the selector shaft seal cover. Image - DIY uaz loaf gearbox cover repair

Rice. 114. Installing the O-ring of the shift shaft cover

Install the rubber O-ring into the hole under the selector lever shaft 23 (see Fig. 105).

Rice. 105. Gear shifting mechanism for cars of the UAZ-3741 family:
1-rod of the reverse gear switch; 2-reverse fork; 3-rod of the plug for engaging III and IV gears; 4-fork III and IV gears; 5-fork I and II gears; 6-rod for inclusion of I and II gears; 7- cotter pin-wire; 8 - plug; 9-washer; 10-shaft for gear shifting; 11-side cover; 12-clutch for gear shifting; 13-blocking spring; 14-gasket; 15-gland cover; 16-shift lever; 17-plug; 18.20-retainer springs; 19-lock plunger; 21-ball retainer; 22-gear selector lever; 23-selector lever; 24-pin; 25-reversing light switch; 26-plug

Install the clutch (fig. 115), thrust washer, thrust spring cup and spring on the shifting shaft. Insert the shaft into the side cover housing and install the gland cover with gasket, secure the cover with three bolts.

Video (click to play).

Rice. 115. Assembling the shaft of gear shifting

Install the selector lever assembly with the shaft (Fig. 116) into the cover housing so that the lever enters the groove in the shift clutch. Lock the lever with a pin, which is hammered in from the bottom.

Turn the side cover over with the machined flange upwards and insert the springs and balls of the III and IV gears and the reverse stem using a mandrel into the retainers of the retainers (see Fig. 113).

Rice. 113. Device for assembling rods and clamps:
a-assembly of the retainer; b-installation of the stem

Install the reverse fork on the stem from the side opposite to the retainer, and after sinking the retainer ball (Fig. 117) into the cover body using a mandrel (see Fig. 113), set the stem to the neutral position.So sequentially collect all the rods (Fig. 118) and forks. Place the keycaps between the rods.

Rice. 117. Assembling the rod and reverse fork

Rice. 118. Assembling the rod and the shift fork of III and IV gears

Fix the forks to the rods with tapered bolts and cotter them with wire (fig. 119), which should not interfere with the movement of the forks. When attaching the forks, the shift clutch lever must be in the groove of the forks.

Rice. 119. Splinting with a wire of the bolts securing the forks:
1-bolt; 2-cotter-wire

Insert the ball and spring of the retainer into the hole in the rods of the 1st and 2nd gears and tighten the plug. At the same time, keep in mind that the spring of the stopper of the 1st and 2nd gears in the free state is longer than the other two springs of the stoppers of the rods.

Install six plugs into the end holes of the cover body, plug into the hole for the shift shaft and rake them out.

Install the selection and shift levers (Fig. 120) on the splines of the shafts and secure them with nuts and lock washers.

Rice. 120. Installation of external levers of selection and switching

The correct position of the levers is checked with the neutral position of the gears in the gearbox after installing the shift mechanism on the gearbox in accordance with Fig. 121.

Rice. 121. Position of the selection lever and the shift lever after installing the mechanism on the gearbox:
A-corresponding to the reverse; B - corresponding to the inclusion of III and IV gears; B - corresponding to the inclusion of I and II gears;
1-lever selection; 2-shift lever (in neutral)

The gearbox cover on the UAZ loaf, like on any other car, is an important part of the gearshift control mechanism - if a malfunction occurs in it, driving a car is either impossible due to the inability to engage the gear, or it is dangerous due to the fact that only some of them work from the steps.

The cover itself is the main part of the gearbox. In this regard, in case of any malfunctions with the lever or suspicious noises from the box, it is recommended to check its condition - perhaps this part needs a complete replacement, and not minor repairs.

Repair of the gearbox cover on a UAZ loaf will differ depending on what kind of problems arose in it.

For example, in a situation where the bushings are worn out, you can proceed as follows: make new bushings and put the cover back, pre-bore a place for it (in this case, the axles are replaced with completely new ones).

Oil dripping from axles due to worn bushings can be eliminated in another way. To do this, you need to remove the levers, cut off pieces of small thickness (which is individually matched to the lid) from a pre-selected hose with resistance to oils and gasoline, insert them on the axles and pull them with levers.

In this case, the levers will turn a little tighter, but the gearshift speed will remain.

Some users, if they find similar problems associated with wear of the splines on the axles and the lack of gears, advise not to repair the cover, but to purchase a new one.

In this case, the new part of the UAZ loaf must be modernized before installation. For this, fluoroplastic ones are placed in place of the rubber bushings.

The removed bushings are cut and installed on the shafts under the levers, which ensures that there is no backlash and that this part of the mechanism is protected from dirt and water.

If any of the gears began to knock out, it is worth checking:

condition of balls and springs in the gearbox coverthat fix the rods when switching speeds - perhaps the cause of the problem lies in their wear, and these components need to be replaced;
then, what is the condition of the gears - this can also cause transmission failures;
bushings - if the problem is in them, then this detail can be strengthened.

The most common cause of knockout gears lies in worn gears and balls, as well as in broken springs.

In addition, before repairing the gearbox cover, you should pay attention to the general condition of the mechanism - perhaps behind a major breakdown, which is clearly visible, several minor malfunctions are hidden, or the entire mechanism is so worn out that it would be wiser to replace it with a new one.

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.

The presence of mechanics on this version of the vehicle is fully justified. It is important to use such a car on rough terrain, off-road. In addition, there will be no towing problems.The gearbox has external shift levers. The lever in the cab moves freely both parallel and perpendicular to its axis.The machine is equipped with a transfer case. In the design of the transfer case on the UAZ 452: drive axle shafts, gears. All of the listed components are located in a cast iron crankcase. The crankcase and cover are connected with nuts. The shift fork rods are securely fixed in the cover.There is a slot, bearings. There is a helical gear wheel for the speedometer drive. The intermediate shaft is fixed on the bearings of the "loaf". This box contains reliable straight-toothed gears.Thus, the gearbox on the UAZ 452 consists of many components and assemblies. This unit needs regular maintenance. Image - DIY uaz loaf gearbox cover repair

This vehicle must be diagnosed if the control began to deteriorate, characteristic squeaks were heard, when a gear change or gear began to spontaneously change. The transfer case of the UAZ should be checked if the adhesion of the wheels to the road has noticeably deteriorated, a hum began to appear, and a growing noise during its operation.

During the passage of MOT, the masters must check the system for oil leaks, the level of lubrication. All worn parts in the transmission system must be replaced with new ones. Also, diagnostics involves the implementation of lubrication of the axis of the levers, adjustment of the front rods.Routine diagnostics in a professional auto repair shop allows you to accurately determine the existing nature of the problem with the box, to eliminate existing problems at an early stage.As a rule, the need to replace the main components at the checkpoint arises with their natural wear and tear.The main reason for oil leakage from the gearbox is the presence of an increased fuel level in the system. For gearboxes on UAZ, high-quality oil should be used. If the liquid is not of the proper quality, then this may cause characteristic noises from the side of the box. When the synchronizer or its parts are worn out, a difficult gear change is always noted. Pay attention to the details of the switching mechanism.When the teeth of the gears are deformed, self-switching of gears is often noted.

It is quite possible to carry out repair of the checkpoint on the UAZ 452 with your own hands. This requires:

a set of wrenches, including the wrenches needed to tighten the nuts;

screwdrivers;

hammer;

chisel;

pliers.

The vehicle must be on level ground. It is necessary to drain the oil from the two boxes by unscrewing the drain plugs. Next, the front seats, the hatch halves, the clutch release fork, the transverse frame, the gearshift levers from the boxes are removed.

We unscrew the clutch pan. We unscrew the fastening of the input shaft spline oiler (on the right on the bell) and push the hose inside the bell. We unscrew the four bolts securing the clutch fork cover, remove the spring, twist the adjustment on the slave cylinder rod and pull out the fork.

We wrap the box with the distributor with rope and hang it up. Unscrew and remove the bolts of the pillows, unscrew the nuts securing the box to the bell. Do this gradually, the nuts on the left side will completely unscrew only when the box has already partially moved away from the bell. Help yourself with a montage. In this case, it is better to prop the engine with a jack, otherwise it will remain on two supports and the “rear” part will go down - it will interfere. When the box finally hangs, gently lower it down. It is better to change the studs in the bell - they experience heavy loads, and 50/50 that the thread on them is damaged. If the car is on the ground, the levers must be removed for ease of pulling it out from under the car. When removing the gear lever, the cover must be held - there is a spring under it.