DIY repair of a five-step vaz 2107

In detail: do-it-yourself repair of a five-stage vaz 2107 from a real master for the site my.housecope.com.

To carry out work on disassembling the gearbox of a VAZ 2107 car, you will need fixing glue, an impact screwdriver, a three-grip puller, oil seals for the primary and secondary shafts, a set of gaskets, and a torque wrench.

Dismantling the gearbox VAZ 2107
1. Drain the oil from the gearbox (see "VAZ 2107 gearbox - checking the oil level and changing the oil").
2. Remove the gearbox from the VAZ 2107 car (see "VAZ 2107 gearbox - removal and installation").
3. We clean with a brush and rinse the outer surface of the gearbox with kerosene or white spirit.
4. Remove the release bearing clutch and the clutch release fork from the gearbox (see "VAZ 2107 clutch parts - removal and installation").
5. Disconnect the elastic coupling of the propeller shaft from the flange on the secondary shaft of the box (see "Driveline transmission of the car VAZ 2107 - disassembly and assembly").
6. Remove the flange of the elastic coupling from the secondary shaft of the gearbox (see "Oil seal of the secondary shaft of the VAZ 2107 - replacement").
7. Disconnect the support of the power unit with a cross member from the rear cover of the gearbox (see "Supports (pillows) of the power unit VAZ 2107 - replacement").
8. Remove the speedometer drive (see "VAZ 2107 speedometer drive - replacement").
9. Remove the reversing light switch (see "VAZ 2107 reversing light switch - check and replacement").
10. Remove the cuff from the ball joint of the gear lever.

11. Using a 10 mm wrench, unscrew the three nuts securing the gear lever housing to the rear crankcase cover.

12. Remove the lever housing and the gasket A under it from the studs.

Video (click to play).

13. Using a 13 mm socket wrench, unscrew the two nuts securing the bracket for the exhaust pipe of the exhaust system.

14. Remove the bracket and take out the square head bolt underneath.

15. Unscrew the five nuts securing the rear cover using the 13 mm socket and box wrenches.

16. Using a 10 mm socket wrench, unscrew the ten nuts securing the bottom cover.

17. Remove the cover and the gasket underneath.

18. Some nuts may come loose with the studs. In this case, after washing the threaded holes and studs with a solvent, apply fixing glue according to the instructions and install the studs in place.

19. Using a 13 mm wrench, unscrew the remaining rear cover retaining nut located inside the gearbox housing.

20. To facilitate the removal of the rear cover, use a screwdriver to recess the 1st and 2nd gear engagement rod. This engages second gear.

21. Tapping the gearbox cover with a hammer with a rubber or wooden striker along the perimeter of the mounting plane, disconnect the cover from the gearbox housing.

22. Remove the rear cover from the studs, and then, turning it clockwise, remove it from the gearbox housing. A gasket installed between the cover and the transmission housing may break. When assembling the gearbox, install a new gasket.

23. We remove from the back cover the plastic plug of the block of gears of the 5th gear and reverse gear, squeezing it out with a suitable tool through the hole in the bearing.

24. Using pliers, remove from the groove in the cover the thrust ring of the bearing of the block of gears of the 5th gear and reverse gear.

25. In order not to damage the rear cover, install it on two wooden blocks and press out the bearing of the gear block of the 5th gear and reverse gear with a hammer (through a mandrel of a suitable diameter).The inner ring of the bearing usually remains on the block shaft.

26. We take out the bearing of the gear block.

27. Remove the secondary shaft oil seal from the hole in the rear cover (see "Output shaft oil seal VAZ 2107 - replacement").
28. Take out the thrust washer of the inner ring of the rear bearing of the secondary shaft.

29. Press out the rear bearing of the gearbox output shaft with a mandrel of a suitable diameter and take it out.

30. Remove the inner ring of the rear bearing from the secondary shaft.

We assemble the bearing by tying its parts with wire or twine.

31. Remove the speedometer drive gear and the ball - pin A of the gear located in the shaft groove.

32. Remove the slinger washer.

33. Using a 10 mm wrench, unscrew the bolt fastening the fork of the V gear and reverse gear.

34. To block the rotation of the shafts, we shift the intermediate gear A of the reverse gear, including the reverse gear. The second gear was engaged earlier when removing the rear cover. If it turns off, press on the rod B. Using a 17 mm socket wrench, weaken the tightening of the bolt securing the block of gears of the 5th gear and reverse gear, without completely unscrewing the bolt.

35. Using a 13 mm socket wrench, unscrew one nut securing the clutch housing to the VAZ 2107 gearbox and unscrew the remaining six nuts with a 17 mm socket wrench.

36. Having wrung out with a screwdriver, disconnect the clutch housing from the gearbox and remove the gasket.

37. To replace the input shaft oil seal with a punch, press the oil seal through the hole in the flange of the front cover of the gearbox.

38. Using the pliers, remove the oil seal from the front cover of the gearbox.

39. Remove the spring ring from the input shaft of the gearbox. The ring has a tapered shape and is installed with a smaller diameter towards the bearing.

40. Using a 19 mm socket wrench, unscrew the bolt securing the front bearing of the intermediate shaft and take out the bolt together with the spring and clamping washers.

41. With a 17 mm socket wrench, finally unscrew and remove the bolt securing the gear block.

42. Moving the Vth gear shift fork along the rod, remove the gear block from the intermediate shaft.

43. Install the gear block in a vice and press the inner ring of the intermediate shaft rear bearing with two large screwdrivers.

We assemble the bearing and tie its parts with wire or twine.

44. Remove the spacer washer from the secondary shaft.

45. Using a 13 mm socket wrench, unscrew the two bolts securing the cover of the rod clamps.

46. ​​Remove the cover with the gasket.

47. From the holes in the gearbox housing of the VAZ 2107, we extract the springs of the rod clamps. Spring A of the lock of the V and reverse gear engaging rod differs from others in rigidity. To distinguish it, it has a dark color and during assembly it must be installed in its place.

48. It is convenient to remove the locking balls using a rubber bulb, creating a vacuum.

49. Remove the V gear assembly with a synchronizer from the secondary shaft.

Read also:  DIY lithium-ion battery repair

50. Remove the spacer ring.

51. Having shifted the gear selection fork, remove the V gear synchronizer sleeve.

52. Holding the fork, remove the intermediate reverse gear from the axle.

53. Remove the 5th gear and reverse gear engagement rod together with the gear selector fork and the rod distance sleeve A. Remove the bushing and plug from the stem.

54. Using a 10 mm socket wrench, unscrew the bolt securing the stem head and remove it.

55. Using a magnetic screwdriver or using a rubber bulb, remove the locking cracker from hole A in the wall of the gearbox housing.

56. Using pliers, unclench the locking ring of the V-gear synchronizer coupling hub and remove it.

57. Remove the hub from the gearbox shaft.

58. Remove the spring washer.

59. Remove the reverse gear.

60.Having pushed out from the inside, we take out the rear bearing of the intermediate shaft.

61. Prying the front bearing of the intermediate shaft by the locating ring with two screwdrivers, take it out.

62. We take out the intermediate shaft from the gearbox housing.

63. Prying with two screwdrivers, remove a part of the inner ring of the rear bearing from the intermediate shaft and assemble the bearing.

64. Using a 10 mm socket wrench with an extension cord, unscrew the bolt securing the 3rd and 4th gear shift fork to the rod.

65. We take out the rod of inclusion of III and IV gears from the hole, at the same time removing the plug from it.

66. From the hole in the rod, remove the blocking cracker.

67. With a powerful magnet or with the help of a rubber bulb, we remove the blocking cracker from the hole in the gearbox housing.

68. Using a 10 mm socket wrench, unscrew the bolt fastening the forks of the 1st and 2nd gears.

69. We take out the stem from the hole, at the same time removing the plug from it.

70. Using an impact screwdriver, unscrew the three screws securing the retaining plate of the intermediate bearing of the secondary shaft and remove it.

71. Prying with two large screwdrivers for the bearing mounting ring, we push the bearing out of the crankcase.

72. Remove the input shaft of the VAZ 2107 gearbox assembly.

73. We take out the front roller bearing from the bore of the input shaft.
The bearing can also remain at the end of the output shaft.

74. Prying with two screwdrivers on the locating ring of the intermediate bearing of the secondary shaft, we pull the bearing off the shaft.

75. We take out the secondary shaft of the gearbox from the crankcase.

76. Holding the axle of the intermediate reverse gear wheel from turning with a 24 mm wrench, unscrew the axle nut with a 19 mm socket wrench.

77. Clamping the secondary shaft vertically in a vice through soft lining, remove the synchronizer of III and IV gears from the shaft.

78. Using pliers, unclench and remove the hub retaining ring from the shaft.

79. Remove the spring washer.

80. Remove the hub of the synchronizer coupling.

81. Remove the gear with a synchronizer of the III transfer.

82. We support the edges of the 1st gear gear on a rigid base (for example, two keys), up to 5 mm thick. We press out the secondary shaft from the gear sleeve through a drift from soft metal.

83. We take out the bushing of the gear wheel of the secondary shaft of the gearbox VAZ 2107.

84. Remove the pinion of the secondary shaft with the 1st gear synchronizer.

85. We take out the hub of the synchronizer clutch of the 1st and 2nd gears.

86. Remove the synchronizer sleeve.

87. Remove the gear wheel with a synchronizer of the 2nd gear from the shaft.

88. Having fastened the input shaft in a vice through soft lining, we push apart and remove the bearing retaining ring with pliers.

89. Remove the spring washer.

90. Leaning the edges of the bearing on a rigid base, press the input shaft out of the inner ring of the bearing through a soft metal drift.

91. Holding the blocking ring of the IV gear synchronizer clutch with your hand, use the pliers to push apart and remove the retaining ring.

92. Gradually releasing the locking ring, remove it and the synchronizer spring of the 4th gear.

93. Similarly, we disassemble the mechanisms of synchronizers of other gears.

Assembling the gearbox of the car VAZ 2107

Note
The tightening torques of the critical threaded connections of parts are given in the appendices (see "Tightening torques of threaded connections on a VAZ 2107 car").

Also, the deformation of the gear shift forks is not allowed, the gearbox forks rods must slide freely without a significant gap in the holes of the gearbox housing.
There should be no traces of binding on the hubs of the gear clutches.
The friction surfaces of the locking rings must be notched. In case of wear of the notch, replace the locking ring with a new one.

1. All gaskets and oil seals of the transmission are replaced with new ones.
2. Before installing the gearbox oil seals, grease the working surfaces of the oil seals with a thin layer of grease.
3. When assembling the gearbox, lubricate all parts with gear oil.
4.When assembling the gear blocks on the shafts, installing the retaining rings, we seat them with a screwdriver until the rings are completely fixed.
5. When installing bearings on shafts, we apply force to the inner rings, and when installing in the holes of the crankcases, to the outer ones.

6. Press the input shaft oil seal into the front cover with a mandrel of a suitable diameter.

Of course, everyone knows that it is better to trust professionals to repair the engine or gearbox of a car. But for every owner of a VAZ 2107, it will not be at all superfluous to know how to remove the box and repair it yourself.

The five-speed gearbox of the VAZ 2107 needs repair when the following signs appear:

  • the appearance of a hum or an increase in the usual noises;
  • Difficulty shifting gears;
  • spontaneous shutdown while driving;