The VAZ 2109 5-speed manual transmission was produced at a plant in Tolyatti from 1987 to 2005 and was installed on all numerous AvtoVAZ front-wheel drive models on the 2108-09 platform. This transmission is designed for torque of power units up to 1.6 liters and 120 Nm. The ninth family also includes 5-speed manual transmissions: 2113, 2114 and 2115. The main thing you need is to constantly monitor its condition, control work processes and not subject it to strong stress. The VAZ 2109 gearbox is reliable, as well as low maintenance costs, since Russian parts are much more affordable than foreign ones.
Technical characteristics of the VAZ 2109 gearbox
| Type | Mechanics |
| Number of gears | 5 |
| For drive | front |
| Engine capacity | up to 1.6 liters |
| Torque | up to 120 Nm |
| What kind of oil to pour | TNK Trans KP 80W-85 |
| Lubricant volume | 3.4 liters |
| Change of oil | once every 75,000 km |
| Replacing the filter | every 75,000 km |
| Approximate resource | 150,000 km |
How the device works
In order for the bearings to provide the appropriate thrust, it is necessary to select the thickness of the rings correctly. The differential flange of the box is connected to the driven gear of the main type transmission. The drive unit of the box consists of the following elements:
- Transfer torque switch;
- Ball type support;
- Traction;
- Lever to change gears and select each gear;
- A rod having an inner end with a fixed lever acting on the switching mechanism.
All these elements are combined into a separate assembly or device attached to the surface of the clutch housing.
VAZ 2109 gearbox device
Gearbox VAZ 2109 - right view
: 1 - clutch cable bracket, 2 - oil level indicator (dipstick), 3 - clutch housing, 4 - clutch release fork, 5 - input shaft of the VAZ 2109 gearbox, 6 - clutch release bearing, 7 — wheel drive shaft oil seal, 8 — protective cover of the gear shift mechanism rod, 9 — rear support of the power unit, 10 — speedometer drive.
Gearbox VAZ 2109 - left view
: 1 - left support of the power unit, 2 - rear cover of the gearbox housing, 3 - drain plug, 4 - gear lock plugs, 5 - reverse gear lock plug, 6 - reverse light switch, 7 — gearbox housing.
Parts of the fifth gear of the VAZ 2109 gearbox
: 1 - rear cover of the gearbox housing, 2 - fifth gear fork rod, 3 - fifth gear fork, 4 - secondary shaft of the VAZ 2109 gearbox, 5 - fifth gear drive gear, 6 - driven gear fifth gear gear, 7 — gearbox housing, 8 — fifth gear synchronizer, 9 — input shaft.
Main components and parts of the VAZ 2109 gearbox and differential
: 1 - input shaft, 2 - secondary shaft, 3 - rod for shifting the third and fourth gears, 4 - fork for shifting the third and fourth gears, 5 - differential, 6 - shift fork for the first and second gear, 7 — shift fork rod for first and second gears, 8 — gear shift rod, 9 — fifth gear shift fork rod, 10 — gear shift mechanism, 11 — reverse intermediate gear, 12 — clutch housing.
VAZ 2109 gearbox - bottom view
: 1 - gearbox, 2 - rear support of the power unit, 3 - oil drain plug, 4 - gear shift rod, 5 - engine, 6 - internal CV joints, 7 - reverse light switch, 8 - left power unit support, 9 - extension.
Details of the secondary shaft of the VAZ 2109 gearbox
: 1 – nut; 2 – ball bearing; 3 – thrust washer; 4 – bearing sleeve; 5 – needle bearing; 6 – 4th gear gear; 7 – bearing spacer ring; 8 – synchronizer blocking ring; 9 – sliding clutch for synchronizer of 3rd and 4th gears; 10 – sliding coupling hub; 11 – third gear gear; 12 – retaining ring; 13 – thrust half-rings of the secondary shaft; 14 – 2nd gear gear; 15 – sliding clutch for synchronizer of 1st and 2nd gears with reverse gear; 16 – retaining ring of the synchronizer hub; 17 – hub of the sliding clutch for the synchronizer of 1st and 2nd gears; 18 – synchronizer spring; 19 – cracker; 20 – retainer; 21 – 1st gear gear; 22 – roller bearing; 23* – thrust washer; 24* – bearing sleeve; 25* – 5th gear gear; 26* – sliding clutch hub; 27* – sliding clutch for 5th gear synchronizer; 28* – thrust plate
REPAIR of gearbox VAZ 2108-2109 replacement of bearings
Removal and installation of VAZ 2109 gearbox
Dismantling the box
If you can hear an incomprehensible noise in the gearbox, the car becomes difficult to change gears or does not want to move at all, you may need to remove this mechanism. Do-it-yourself repair of a VAZ 2109 vehicle can be done in any garage, having all the necessary tools at hand. The VAZ 2109 has a rather complicated gearbox removal, so you should prepare for this procedure in advance.
The box is located deep enough, so it is almost impossible to remove it alone. In this case, you may need special crowbars, the help of other people and some tools in order to properly disconnect it. In general, you can seek help from a service center, where the service will be carried out using special equipment. But, you can repair it yourself by removing it carefully without damaging other important parts.
Characteristic
As we said earlier, a 4-speed transmission was also installed on the car. The assembly of the gearbox for the VAZ-2109 of this type did not last long. Therefore, it is now very difficult to meet “short-winged” cars with a 4-speed manual transmission. It's practically a rarity. 95 percent of the “nines” came with a more modern, 5-speed manual transmission. It was two-shaft, with synchronizers in all gears (except reverse). Structurally, this gearbox is combined with the main gear and differential. It differed from the 4-mortar in a different location of the crankcase ventilation pipe. It was located on the clutch housing (previously it was on the rear cover). A dipstick also appeared. But the gear ratios remained the same.
In Russia, these cars stopped being produced back in 2004. But you can still find spare parts for the VAZ-2109 gearbox in stores. Their price is quite reasonable. If necessary, you can buy a complete transmission for 5-6 thousand rubles.
Malfunctions and their elimination
Gearbox repair largely depends on the nature and type of fault. There are several options for the breakdown of this unit, in each of which appropriate actions should be taken to eliminate them.
In most cases, problems with the gearbox are eliminated by dismantling and disassembling it. Do not take on this type of work without the proper skills and experience.
What to pay attention to
So, following the instructions, we disassemble the gearbox of your VAZ 2109. Along the way, pay attention to the following points:
- Bearings. When they wear out, a noise from the box occurs. Plus, worn bearings negatively affect the condition of other gearbox elements;
- Synchronizers and sealing washers. If their condition leaves much to be desired, then the gears shifted poorly precisely because of them. Replace them;
- Clutch system, cotters, coupling hub clamps. All this must be replaced separately if there are signs of wear or defects;
- Blocking rings, synchronizers. If there are chips or nicks, don’t even think about alternative solutions, replace them immediately;
- Bearing tracks. Over time they wear out. If signs of wear are found, perform a complete replacement. In this state, they were only a short time away from breaking;
- Gap between gears and locking rings. Normally it is no less than 0.6 mm. In case of deviations, there is only one solution - replacing the rings;
- Retaining rings. If elasticity is lost, these elements must be changed, since they will no longer be able to perform their functions.
When assembling the gearbox, do not forget to lubricate the new gaskets with a layer of lithol. And when pressing the oil seals, do it with the working edge inward. The metal clip should be located on the outside.
During the process of reassembling the gearbox, all rubbing components should be treated with oil, and do not forget about the sealant for connecting the clutch housings and gearbox. Doing everything yourself is quite possible.
If you find an error, please select a piece of text and press Ctrl+Enter.
The transmission goes out
If you lose speed while driving, the gear assembly is most likely worn out. The locks on the gear and clutch also fail. These elements are replaced entirely with new ones.
It is worth noting that the gear on the “nine” can also fall out due to too fast shifting. The manufacturer recommends a two-second pause when switching to increased speed. If you continue to ignore this problem, you may encounter failure of the synchronizers.
Each box has its own noise limit, which is not a symptom of a malfunction. The transmission has gears that constantly rub against each other. And no matter how technologically advanced the design is, it is impossible to completely eliminate sound. As for the 5th gearbox VAZ-2109, its noise regulation is 78 dB. Anything higher is equivalent to a malfunction. And the box may make noise due to insufficient oil level in the box. As you know, gear oil has a higher viscosity than motor oil. And it is not sprayed by the pump. This oil is located in the gearbox housing. When the gear rotates, it dips itself into the lubricant. If the liquid level is below the permissible level, the element will run dry. This entails increased gear wear and wear. As a result, even if the oil level is restored, the problem will not disappear.
Axle system
Five-speed gearbox
In the structure of the gearbox, or rather in the housing, two axles are attached. A pair of locking brackets, a bushing and a three-arm lever are installed on one axis, which makes the device more reliable. The second axis, which penetrates the hole of the locking type brackets, is determined by the hub, which acquires the function of preventing rotation. Characteristic shoulder levers:
- The first arm is designed to include the transmitting torque of the forward stroke;
- The second type of arm is designed to trigger the reverse transmission element;
- The third type of shoulder acts on the shift lever of the transmitting elements;
- In this case, the lever shift hub is equipped with a lock;
- A reverse fork is also mounted on the axle.
Disadvantages, breakdowns and problems of the Lada Samara box
The reliability of the manual transmission is weak, the transmission is famous for unclear shifts and howling
Gears switch off spontaneously due to wear of the locks on the couplings and gears
The box hums most often due to a lack of lubrication or when the bearings are damaged.
A strong crunch when switching hints at a quick replacement of synchronizers
The weak point of the gearbox is the rocker; it often requires repair or replacement
Another common problem is oil leaks from different seals.
You can contact the site administrator by email: [email protected]
All texts were written by me, are authored by Google, included in the original Yandex texts and notarized. For any borrowing, we immediately write an official letter on company letterhead in support of search networks, your hosting and domain registrar.
How to check for defects
Before assembling the gearbox for the VAZ-2109, the parts must be reassembled for defects that require elimination:
- What condition are the bearings in? If they are heavily worn, this will lead to a hum.
- Inspect the synchronizer and the material sealing the washers - wear provokes poor gear engagement.
- Rings and synchronizers with nicks and deep chips require replacement.
- Measure the gap between the gears and the locking rings; ideally it should not exceed 0.6 mm.
Operating principle of the gearbox synchronizer
Anyone who has ever driven a car knows the purpose of a gearbox. However, both its structure and operating principle often remain a mystery to many. In general, this may be correct, in any case, this approach has a right to exist, however, without studying the box in detail, it is worth touching on such an element as the synchronizer.
- Why are gearbox synchronizers needed?
- Transmission synchronizer operation
- Gearbox synchronizer, care, operation
Gearbox Requirements
- high efficiency
- ease of control and shock-free switching and quiet operation
- inability to engage two gears or reverse at the same time when moving forward
- reliable retention of gears in the engaged position
- simplicity of design and low cost, small size and weight, ease of maintenance and repair
To satisfy the first requirement, it is necessary to correctly select the number of stages and their gear ratios. By increasing the number of stages, better engine operation is ensured in terms of dynamism and fuel economy. But the design becomes more complicated, the overall dimensions and the weight of the transmission increase.
Gears are switched using movable gears, gear couplings, synchronizers, friction or electromagnetic devices. For shockless shifting, synchronizers are installed, which complicate the design and also increase the size and weight of the transmission. Therefore, the most widespread are those in which higher gears are switched by synchronizers, and lower ones by gear couplings.
Useful tips
It is extremely important to monitor the serviceability of the gearbox, and if signs of breakdown are detected, fix them immediately. Do it yourself or with the help of a car service - this is your personal decision.
When operating a car in city conditions, you have to change gears more often. Therefore, it is recommended to use motor oil here. This ensures that the synchronizers remain effective longer. Transmission oil is better suited for highways, increasing the life of bearings and gears, although the synchronizer lasts less.
Oil disappears
Unlike engine oil, rarely does anyone check the transmission oil level. But in vain, because sometimes you can simply get a dry dipstick. If measures are not taken in time, increased noise will appear (since the gears are running dry). For what reasons does oil leak from the box? There are several factors:
- The crankcase cover does not fit tightly.
- Worn shaft seals.
- Loose oil drain cap.
- Cracks in the transmission pan (solved by replacing the element).
It is worth noting that if there is no or insufficient oil level, the box does not operate at its temperature range. Because in addition to its lubricating properties, this liquid takes on part of the temperature loads. If there are oil leaks, the box may simply overheat.
The car jerks when starting, it is impossible to shift into gear
The cause of the malfunction is not always the VAZ-2109 gearbox itself. Repairing it may not save it if the clutch assembly is faulty. But it is this system that interacts with the gearbox and engine. It is through the clutch disc that torque is transmitted from the flywheel to the transmission shaft. Typically, this unit serves at least 120 thousand kilometers. But many “nines” have old-style odometers, which reset to zero at 100 thousand.
It is difficult for the driver to control when this or that part in the clutch has been replaced. If the car jerks at start-up and the transmission is difficult to turn on, most likely the disc has been worn out. The plates wear out on it and the damper springs fly out. The petals on the clutch basket are also bent. We have already said about bearings that they are noisy. All this together affects the behavior of the car on the road.
