Dismantling and assembling the secondary shaft on a Volga GAZ 31105 2004 - 2009 car

Transmission bulkhead

To make repairs and replace parts, you need to know how to disassemble the Gazelle box itself.
Yes, you will have to disassemble it anyway. There is a chain of actions here:

bearing cover – rear input axis (bushing) – breather – crankcase separation – fastening the gear shift fork (after putting the car in reverse mode) – lever body and gasket – clamp fittings – switch rods (order – 1, 2, 5, rear, 3, 4) – reverse axle and remove the rear shaft bearing retainer ring – remove the shafts themselves.

The diagram may seem complicated, but if you look at the box in person, everything will become clear. This is what self-removal or replacement of the Gazelle gearbox looks like.

Installation of the entire system is carried out in reverse order. The main thing is to remember to carefully lay out the removed parts so that you don’t get confused during the reverse process.

Manual transmission mechanism

A 5-speed gearbox is a gear reducer that transmits torque from the engine to the wheels. The new gearbox has:

• 2 craters connected by bolts;
• primary, intermediate, secondary shaft. The first and second mechanisms are connected to the cardan and crankshaft.

Appearance of manual transmission on Gazelle NEXT

The intermediate shaft has teeth for first and reverse gears, as well as a gear block and a speedometer drive:

• synchronizers;
• speed fastening components;
• single gear activation blocker;
• device for damping vibrations.

Watch the video: Repairing the gearbox on Gazelle Next.

In 2016, when improving the Gazelle Next, the developers slightly changed the gearbox design:

1. changing the width of the gear rims;
2. installed the intermediate plate of the second and intermediate shaft;
3. bearings were supplied of improved quality for increased load capacity;
4. flange contact of cardan transmission.
5. Synchronizers from Hoerbiger.
6. Joystick handle.

This is what the Gazelle Next gearbox looks like

The designer also strengthened the rear axle for load capacity, and with all this there is a Chinese diesel power unit.

This modernization gave a positive result - high reliability, increased service life, torque transmission of 330 Nm.

External view of the Gazelle Next power plant

During the first inspection of the car, experts give recommendations on how best to run the car and at what speed the speed should be changed. Many car enthusiasts do not pay attention to this fact, since everyone considers themselves professionals. As a result, a problem occurs with the box - it makes noise, knocks, and behaves incorrectly.

Video instructions for gearbox repair

Gearbox VAZ 2110 5 mortar device diagram
It is more convenient to work together.

We screw the filler and drain plugs into place.

Remove the power unit support.

Remove the reverse light switch.

Remove the speedometer drive.

Remove the coupling with the bearing and the foam rings of the front cover.

Using a 12mm wrench, unscrew the three bolts securing the bearing cover (the bolts are installed on the sealant).

Read more: How to distinguish a forged wheel from a cast one

Remove the cover with gasket.

When installing it later, pay attention to the coincidence of the oil drainage channel in the cover and the hole in the crankcase

Using a screwdriver, we remove the cuff of the input shaft from the cover (when disassembling the gearbox, we replace all cuffs regardless of their condition).

Using a mandrel or a head of suitable diameter, we press in a new cuff.

Using a 13mm wrench, unscrew and remove the bolt securing the reverse gear axis bushing to the front crankcase

Using a thin screwdriver, pry up and remove the retaining ring of the input shaft bearing

Using a 12 key, unscrew and remove the breather.

Using a 12mm wrench, unscrew the ten bolts connecting the front and rear crankcases (the two bolts passing through the mounting sleeves are longer than the others).

11

Carefully tapping with a hammer through a brass mandrel, uncouple the front and rear crankcases

In this case, you must not strike the end of the input shaft, as the synchronizers will be damaged.

We disconnect the gearbox housings

Carefully, trying not to damage, remove the sealing gasket

We remove the adjusting shims from the bore under the intermediate shaft bearing in the front crankcase (they may not be there).

In this case, the axial clearance in the bearings is established only by the inter-crankcase sealing gasket.

In 2013 Russia saw the new Gazelle Next. The developers of this model focused on the car's cabin. Everything for the comfort of the driver and passengers. But it was not taken into account that cars such as Gazelle Next drive long distances. And for this you need not only comfort in the cabin, comfortable seats, but also order under the hood of the car. The factory installed a 5-speed Gazelle Next gearbox. The new manual transmission has an assembly with parts from different manufacturers. When passing 40 thousand, switching speed from 2 to 3 or from 4 to 5, the driver begins to hear noise, crackling and other strange sounds. To determine what kind of sound it is, you need to have at least a superficial idea of ​​what it is?

This is what Gazelle-Next looks like

Instructions

1. We go into the hole.
2. Pour out the oil (one liter is enough).
3. We get rid of the wheel bolts and remove the nut from the bearing (front hub only).
4. Where the lower ball joint is located, unscrew the two bolts.
5. Now we direct the lower lever down. And pull out the end of the drive.
6. Get under the car and pull in the drive.
7. Using a screwdriver, remove the oil seal itself.

There is a new oil seal in your hand.
Now we take the new part and insert it. There is no need to press all the way. Now everything is the other way around, push the box back, point the lever up, tighten the bolts, put on the bearing. And most importantly, don’t forget to pour the oil back in!

Done, the Gazelle gearbox repair was done with your own hands.

We wish you a smooth and problem-free ride! Remember that many problems can be solved on your own, without resorting to service centers and expensive procedures. You can learn everything even the first time.

Features of the GAZelle gearbox: design and repair

Gazelle business wiring diagram

The gearbox is a component of the transmission. It changes the gear ratio and torque transmitted from the engine to the vehicle's drive wheels. The gearbox has a very impressive service life and is capable of functioning flawlessly throughout the entire life of the vehicle. But this requires timely and high-quality checkpoint maintenance.

Today we will disassemble the gearbox of a Gazelle car. Let's add oil. To do this you will need a 12mm hexagon. If chips are found on the plug, it means there is wear in the gearbox.

The manufacturer recommends filling 1.2 liters. oil into the gearbox, but we recommend pouring at least 1.5 liters to avoid “oil starvation” in fifth gear during overload.

We disassemble the gearbox. For convenience, clamp it in a vice with the shank down, at an angle.

We unscrew all the bolts with a 12 mm socket, starting from the front flange and the input shaft, then the gearshift lever cover. It is more convenient to unscrew the bolts connecting the box body using a head with a “cardan”.

Using a 13mm socket, unscrew the bolts securing the reverse gear.

Remove the input shaft flange and clean off the remaining gasket and sealant on the housing.

Next, you need to remove the retaining ring, otherwise you will not be able to halve the box.

Remove the top half of the housing.

Unscrew the forks. Use pliers to remove the gear shift rod.

Be careful, the bearings may fall out. The outer rods are removed first, then the central one. It has an additional fixation rod.

If the rod is worn out, only the working part must be replaced. It is not advisable to completely change the stem.

We remove the forks and check the wear of the “crackers” - if they are good, we leave them.

The following operation must be carried out with an assistant. Use a pair of narrow-nose pliers to press the stopper and hold it, lifting the gear block until it disengages from the clutch.

We take out the gear block and begin an inspection; if chips are found on the gears, they need to be replaced.

When disassembling the “box”, we recommend replacing the input shaft seals and shank seals.

Remove the input shaft. Inside the shaft there are 14 rollers that spin on the shaft. To replace the bearing, you must remove the retaining ring.

Since the bearing is seated on the shaft, it must be knocked out. All other transmissions are analyzed by analogy. The retaining ring is removed, the gears are removed, and an inspection is carried out for chips.

After completion of the repair, assembly is carried out in the reverse order.

Source

Gazelle gearbox repair, diagnostics, replacement of gearbox bearings

Recommendations for extending the service life of the unit

Without proper care, the Gazelle gearbox quickly breaks down. Some explain this by the mismatch of the unit for a truck. As you know, the box used here, albeit modified, is from a passenger car. Therefore, the slightest overload or prolonged operation has an extremely negative effect on the resource. Already by the 80,000th mileage, gears begin to fly out, crackling and noise appear.

First of all, you need to change the oil correctly and promptly. The replacement interval is determined by the manufacturer at 50,000 mileage, but it is better to do this twice as often. You need to fill in not the lubricant that comes from the factory (cheap TAD 17), but higher quality analogues. For example, GL-4 or 5 with a viscosity of 75W-90.

• do not load the car above the norm of 1.5 tons;
• drive on good roads, avoiding gravel and complete off-road conditions;
• monitor the clutch, refill technical fluids on time.

Repairing and disassembling the Gazelle gearbox is not an easy task, but following the instructions, you can handle the operation yourself. If something doesn’t work out, you can always take the box to a service center or call a specialist to your home.

Features of gearbox repair

Connection diagram for engine sensors gazelle 406 carburetor

Do not think that repairing a Gazelle gearbox with your own hands is easy. The gearbox is a complex mechanism that transmits torque from the engine shaft to the drive wheels. Your safety depends on it and the slightest deviations in the operation of the gearbox signal the need for diagnostics. You shouldn’t be afraid of difficulties - after all, there may not be a service station nearby, and step-by-step instructions will help even a novice car enthusiast to successfully cope with the matter.

Features of Gazelle gearbox repair

The Gazelle gearbox is reliable and durable. But constant loads sometimes lead to its breakdown. Gazelle gearbox repair will require the driver to:

• knowledge of vehicle hardware;
• the ability to remove the gearbox, disassemble it, and then reassemble it and put it in place;
• strict adherence to safety regulations;
• attention, accuracy and patience.

Important! You should not repair the gearbox alone - you need a partner

How does the gearbox work on a Gazelle?

The gearbox is manual, five-speed. Comprises:

• two aluminum crankcases (connected with 10 bolts);
• primary and secondary shafts (connected to the crankshaft and cardan);
• an intermediate shaft with cut teeth for 1st gear and reverse gear, a pressed-on gear block and a speedometer drive gear;
• inertial synchronizers;
• spring-loaded balls for fixing gears;
• locking gears at the same time;
• lever damper device;

The Gazelle gearbox design allows you to respond to the first symptoms in time to prevent more severe consequences.

When is transmission repair necessary?

The signal for urgent repair of the Gazelle gearbox is:

1. Inability to change gear or if it is difficult to do so.
2. When trying to change gear while driving, a loud cracking sound is heard.
3. Shifting gears on your own (risks an accident).
4. Any extraneous noise, crunching, knocking in the gearbox.
5. Routine diagnostics of the Gazelle's gearbox must be carried out every 300,000 km.

Main gearbox malfunctions on GAZ 3307 vehicles

Long-term operation of Gazelle cars has made it possible to compile a list of the main malfunctions of the Gazelle gearbox and their possible causes:

• The cause of the humming noise during operation is the destruction of worn parts or loosening of the fastening bolts;
• Crunching in the gearbox - destruction of bearings;
• Crackling sound when switching - synchronizer rings are worn out;
• Difficulty shifting gears - jamming in the gearbox drive, wear of gears, burrs, etc. (needs to be disassembled and inspected);
• Self-switching off speeds - misalignment of gear teeth, wear of rods and forks, loosening of the gearbox and driven shaft fastenings;
• Oil loss - crack in the crankcases, loose fasteners, wear of the gasket, oil seal, etc.

Important! The causes of some malfunctions (noise, difficult shifting, self-disengaging gears, etc.) may be clutch problems (incorrect adjustment, premature release of the pedal, etc.)

Necessary tool for removing and disassembling the box

For repairs you will need an inspection hole or overpass, as well as tools:

• a set of keys (for 10, 12, 13, 14, 17, 19);
• Screwdriver Set;
• beard;
• wooden blocks;
• pliers (pliers);
• mount;
• pullers;
• hammer;
• needle file, sandpaper;
• brass pad or copper hammer;
• mandrel for old oil seals.
• container for draining oil;
• rags;
• CV joint-4, transmission oil, GOI paste.

The most common symptoms and troubleshooting methods

Despite the structural simplicity of the unit, repairing a Gazelle gearbox with your own hands involves serious work. Without the proper knowledge and skills, it is better not to touch the unit, so as not to make it worse. To replace damaged parts, the box must be dismantled and disassembled.

There is a noise in the box

Most often, a sign of a mechanical malfunction is a dull hum or crunch, indicating weak fixation or destruction of the bearings. An unpleasant cracking sound is also possible, indicating damage to the synchronizer rings. Often the box howls, and in completely different ways. The strength of the sound and its character depend on the speed of movement, the specific gear, and the duration of driving.

It is noteworthy that the characteristic noise does not always indicate a gearbox malfunction. Especially if the elements of the box have recently been replaced. In this case, the howling will only be a sign that the parts have not yet gotten used to it. Often, the crunching of the gearbox is confused with malfunctions of the clutch or other related units. And any experienced Gazelle driver will confirm that until you disassemble the box, the specific cause of the noise can only be determined with a 50 percent probability. But a competent bulkhead will help you immediately find the problem area. Before this, of course, you need to check the oil level. If it's ok, you need to disassemble the gearbox. Anything can turn up during the troubleshooting process. For example, there may be a mismatch in bearing markings, missing washers, or incorrect sizes.

Thus, noise in the Gazelle gearbox is caused by wear of bearings, gears, synchronizers or their destruction, breakdown, as well as a low level of MTF or its poor quality. The alignment of the crankshaft and crankcase is rarely disturbed, but it doesn’t hurt to check the runout of the mounting hole for the box.

Difficulty shifting gears

If it becomes difficult to change gears, this indicates one of the problems:

• synchronizers or gears of a certain gear are worn out;
• the lever or other switching mechanisms are damaged - most often the fork;
• problem with the clutch - it does not engage completely, the pedal drive cable is loose, the driven disc is damaged.

Often, poor gear engagement is due to design flaws in synchronizers. When the clutch plate is pressed against the flywheel or pressure plate, the bearing in the crankshaft creates resistance. This is enough to block the inclusion of speeds.

It also happens that it is difficult to change gears on a warm engine, but when it is cold everything goes like clockwork. The point here is that initially there is a thick layer of lubricant between the synchronizer thrust ring and the gear. After the temperature rises, the oil liquefies, the ring and gear are rubbed almost dry, and the coupling rests against the teeth of the ring. Either a high-quality grip, such as HOLA, or another MTF compound will help.

Possible malfunctions during operation of the transfer case

Transfer case malfunctions are similar to problems with a conventional transmission. Among them are:

• breakage or chipping of gear teeth;
• gear shifting spontaneously;
• Noise is noticed when the gears operate;
• 2 gears are switched on simultaneously;
• Gears are difficult to engage.

Oil leaks from the transfer case due to damage to the sealing gasket or wear of the seals. A crack in the housing may also be the cause.

Gear noise when shifting gears occurs when the clutch breaks down or is not adjusted correctly. It is necessary to replace the failed part. But noise when the Gazelle moves may indicate poor lubrication of parts or wear of bearings.

Knowing these and other faults, you can easily prevent more complex breakdowns of your car. We hope that these simple features of operating the Gazelle transfer case will be useful to you!

Table: malfunctions of the Gazelle box according to the nature of the noise

Now you know how to remove and rebuild the Gazelle gearbox yourself.

Source

Possible problems with the Gazelle gearbox

Disassembling and repairing a gearbox (5-speed), regardless of the make and model of a Gazelle car, is always a crucial moment, anticipating serious work. Owners of commercial vehicles encounter this problem most often, so they have replaced it more than once. But is it worth it, having seen an advertisement on the Internet for repair of a Gazelle gearbox, to run there, jingling your wallet? Not necessary. It is quite possible to get by with an assistant, diagrams of the gearbox design and instructions for the necessary work. This is enough to repair or replace worn parts yourself.

The presence of a huge experience base on problems with the Gazelle box allows you to almost accurately draw up a “problem-cause” diagram.

Most often, the problem list looks like this:

• If during operation you hear a dull hum from the side of the box, this is a sure symptom of loosening of the fixing fasteners. Also, such a sound can signal the death of the most worn parts;
• The characteristic “crunching” sound is most often produced by worn-out bearings. In general, to avoid such a problem, it is recommended to replace bearings after 90 - 100 thousand km. On your own, or as planned at a service – it’s up to you to decide what’s convenient for you
• If gear shifting is accompanied by an unpleasant crackling noise, then it makes sense to think about replacing the synchronizer rings;
• There can be many reasons for difficult gear shifting. Perhaps the box drive itself is jammed or jammed. But there may also be wear of a certain group of parts (gears, burrs, etc.). Only a bulkhead will tell you the exact reason.
• Oil leak. According to statistics, this is the most common problem that is addressed to workshops. As in the case of oil loss in the engine, the main culprit here is hardened or, on the contrary, worn out gaskets and seals. But it may turn out that much more serious cracks in the crankcases are to blame.

It may turn out that the indirect cause of the problems described above is incorrect clutch adjustment. Or simply working with it incorrectly. For example, a constant change of minibus drivers and their different qualifications can damage the gearbox up to the “fifth gear”.

Automatic transmission for GAZelle Next

Recently, many GAZelle Next car holders are installing imported parts on their car, as they show their best side, functionality and performance are much better than factory parts. With the installation of the Toyota power unit, an automatic gearbox is also installed. A lot of drivers, complaining about traffic jams in the city, dream of such an opportunity. Automatic transmission offers many advantages.

Interior view of Gazelle Next automatic transmission

• Safe management.
• There is no need to work with your right hand (shifting gears) and left foot (clutch) every time.
• Traffic safety.
• Smooth and soft control.
• Reduced engine wear.
• Good cross-country ability of the car on dirt roads, as well as on snowy or muddy roads.

Despite such bright positive aspects of automatic transmission, there are disadvantages:

1. Fuel consumption increases.
2. The maximum speed will be reduced.
3. In case of emergency driving (skidding in winter), the automatic transmission will not help.
4. The oil needs to be changed more often than with a manual transmission.
5. Expensive repairs.
6. Low load capacity.

And one more drawback. According to car enthusiasts, if a loaded Gazelle Next travels long distances, the service of the automatic transmission will be limited to a year of operation.

ᐈ Gazelle gearbox repair Kyiv - Prices 2022, Cost of Services

The All-Ukrainian TV channel in the program “Breakfast with 1+1” interviewed Roman Kirigetov, the founder of the Kabanchik.ua project, live about how the service works and how to safely order the services of private specialists in Ukraine.

Professional automatic transmission repair in Kyiv is a complex repair service that is in demand among many car owners. The most common cause of automatic transmission streaking is improper operation. To find and eliminate the cause of failure, specialized equipment and professional experience from a master are required. You can choose a specialist with in-depth knowledge to carry out repair work using the Kabanchik service.

When is gearbox repair needed?

Of course, the easiest way is to use the gearbox correctly and avoid breakdowns. To do this, it is enough to avoid a sharp increase in speed, when driving on sand, wet and snow-covered asphalt, to avoid slipping, and not to exceed speeds above 150 km/h (or, alternatively, change the oil in the gearbox more often). But if the conditions cannot be met, the gearbox will need to be repaired - the signs of its relevance are as follows:

• the oil has become black or dark brown;
• there is a sharp burning smell;
• there is noise in the automatic transmission;
• the car drives jerkily;
• oil leaks out.

Any of these signs is quite serious, so you need to contact a specialist immediately. What is the repair process? This is a restoration of functions according to factory transmission requirements. Given the complexity of the unit, only experienced craftsmen with specialized equipment for diagnostics and repair work should be allowed to work.

Features of automatic transmission repair

The transmission is the key element of the car. Modern models feature an electronic transmission control system instead of the outdated hydraulic one. Therefore, the qualifications of the master must be appropriate. Types of services for automatic transmission restoration:

1. Automatic transmission diagnostics and repair. During the process, it is possible to conduct a test visit with a technician and use computer diagnostic tools to identify hidden breakdowns.
2. Opening the pallet. This is necessary to analyze the condition of the oil and search for worn components and materials.
3. Troubleshooting. Compiling a list of detected breakdowns and methods for eliminating them.
4. Repair of gearbox valve body and other components. If possible, the technician will carry out the work without removing the transmission.

The repair can be partial (it is carried out without removal), or major (it is assumed that key elements are replaced). Also, if necessary, the technician will completely replace the transmission with a new one with similar characteristics.

Who can I order gearbox repairs from?

Gearbox repairs and maintenance are complex tasks. However, all car owners are interested in optimizing the cost of a technician’s services, but without sacrificing quality. This is possible if you entrust the work to private, proven contractors who work without any extra charges. Our service will help you find such a specialist or a small team.

Cost of repair of automatic transmission and manual transmission Price, UAH.

You only need to complete the task - indicate the conditions, offer a price and the optimal completion time for you. Just 5 minutes is enough to select a specialist: from several candidates, with the help of reviews, ratings and portfolios, you can select the best specialist. All performers on the site are verified - this guarantees the safety of the work performed, along with an affordable cost and high quality.

How to repair a Gazelle gearbox

23.10.2017

Gazelle gearbox repair is a complex undertaking that needs to be prepared for in advance. The gearbox operates by transmitting torque to the wheels from the motor shaft. It is worth understanding that the slightest malfunction in the functioning of the transfer case can threaten your safety. If there is no service station nearby, you can repair the fault yourself. If you strictly follow the step-by-step instructions, even a novice motorist can carry out this procedure without any problems.

What are the faults of the Gazelle gearbox?

Gazelle gearboxes are rightfully considered one of the most reliable and durable, but even they can become unusable due to high loads. In order for the replacement of the Gazelle gearbox to go without a hitch, you must know the hardware of the car, study the diagrams, be careful and patient, and also follow the safety rules and understand the principle of operation of the Gazelle 4x4 gearbox.

Gazelle repair may be required in some cases:

difficulty changing gears. This snag occurs due to the lack of fluid in the cylinder or due to the presence of air in the hydraulic drive. In addition, you can check the locking bolts, which often need additional tightening, as well as the transmission intermediate shaft. You can observe how the device jerks in neutral, and the transmission howls. Another sign is that in 4th gear, fifth or second, the device makes a howl, a lot of noise;

The gearbox engages with noise and crackling noise when starting. In this case, the synchronizer blocking ring on the transfer case could be worn out or deformed. Also check the power take-off. It is advisable to replace the blocking ring or power take-off box, and to ensure that the new element fits in without problems, use lapping paste. In addition, check the condition of the input shaft, how the mortar works, whether the car is noisy in neutral;

random shutdown of manual transmission

If you notice such a problem, first of all check the fastening nuts to the clutch housing, as well as the condition of the gazelle gearbox linkage. In addition, the couplings could wear out (worn out teeth), as well as the locking springs (they can either wear out or weaken)

You may also need to adjust the intermediate shaft and input shaft;

the appearance of extraneous noise. In order to get rid of them, it is necessary to replace bearings or damaged gears, add oil to the crankcase or check its alignment with the crankshaft.

To repair a Gazelle gearbox, you must know everything about the structure of the transfer case, because disassembling the gearbox is not an easy task. This is also necessary to determine the type of failure. The most popular reason for Gazelle owners to replace the gearbox is oil leakage. It occurs due to worn out seals or bushings, worn out gaskets, as well as poor sealing of the plugs. In this case, you will need to add or change the oil in your car, as well as replace the bushing.

How to replace a gearbox on a Gazelle

How to remove the box? Replacement of the gearbox is carried out on an overpass or inspection pit. First, drain the oil from the crankcase. Now we remove the cardan. To do this, arm yourself with a file and put a notch on the connecting unit and the continuation of the gearbox on the gazelle. Now remove the support fasteners using keys thirteen and twelve.

Using keys seventeen and fourteen, remove the fixation of the cardan to the flange of the main gear gear. We remove the shank and insert a rag into the hole. Now we need to get the lever to install the gearbox.

To do this, we get rid of the cover and the top of the lever inside the cabin, unclench the bushing, remove the rubber cushion, floor seal and cover, cap and the lever itself.

Device diagrams:

1 2 3 4

Next, disconnect the speedometer from the transmission along with the rear light switch. Now you can remove the transfer case. How to disassemble the gearbox housing? To do this, get rid of the fixation of the exhaust pipes and bracket, disconnect the transmission from the clutch housing, and create protection from a wooden block for the cylinder head. We proceed to removing the transverse fixation of the transfer case and remove the device. Be careful as its weight can reach 30 kg. Install a new element. Be careful not to damage or miss the stepped transfer case.

Design overview

The assembled design of the new sample synchronizers (hereinafter referred to as NO) looks like this:

The hub with the clutch, the ring gear and the synchronizer itself were changed. Next, let's look at the differences in more detail. There are 6 holes on the crown of the NO gear into which a brass ring is inserted:

Old-style gears have a different type of crown; instead of holes, they have a cone with which a brass ring is in contact:

For comparison, on the sides there are NO synchronizers, in the center there is a brass ring of the CO synchronizer:

The main difference between synchronizers is that in the old one a brass ring rotates with the clutch, in the new one it rotates with the gear, and the outer and inner rings rotate together with the clutch:

The difference between the HO hub is the grooves for the projections of the inner ring:

The wear of the NO synchronizers is determined by the gap from the end of the outer ring to the gear:

As measurements have shown, the inner ring practically does not wear out:

The brass ring is wearing out, as can be seen from the cross-section of the oil channels:

The second place of increased wear is the teeth of the outer ring

With regular replacement and sufficient oil level, there should be no wear in the remaining synchronizer components:

When assembling the secondary shaft, it is important to position the rings correctly, as in the photo. Otherwise, trouble may happen, but more on that in the next part:

Next, I will try to explain how the synchronizer works. Common to all synchronizers is the movement of the teeth of the synchronizing ring relative to the coupling - but it must be within one tooth of the coupling and when the coupling moves, it must fall on the outer side of the tooth of the synchronizing ring, with further sliding of the tooth along the tooth, displacing the synchronizing element to the center, into the gap between clutch teeth. Depending on the direction of torque transmission, these will be different positions:

The fundamental difference between the NO and CO synchronizers is that the CO synchronizers have a working surface on one side, while the new type synchronizer has a brass ring clamped on both sides, that is, the working surface is twice as high. Also, the new type of synchronizers have vertical slots for oil drainage, which increases the speed of gear engagement:

News

After a long illness, on June 19, 2022, master Andrei Vladimirovich died at the age of 59. He was an exemplary family man, a good father and grandfather, a master from God, a real man. We all remember him and mourn him immensely. This site will continue to operate, but it is unlikely to be updated. 04/28/12 New version of our free program for GSK - AVgarage

! 12.11.10 Replacing the rear silent blocks of the lower arm of the front suspension on MMC Lancer IX in pictures. 25.11.09 We kindly ask customers to pick up spare parts forgotten at the service within 2 weeks. 02/12/08 Replacing the camshaft oil seal on the MMC Space Runner (4G93 engine) in 5 minutes. 02/05/08 The master installs a VAZ gearbox on IZH “Oda” cars with a Zhiguli engine. 01/25/08 Repairing a gearbox and replacing a clutch on a Mitsubishi Space Runner in pictures. 01/14/08 From now on the site will live at this address. 01/30/07 Material has been added about the design and installation of the secondary shaft of the gearbox of rear- and all-wheel drive VAZs of the new model. 01/20/07 Work on a new version of the site has been completed. 08/12/05 New pages have appeared - Useful and Cooperation. 06/21/05 The Conference is open on the website. 03/19/05 A section on repairing the transfer case of all-wheel drive VAZs has been added. 03.13.05 Information has appeared about the design and malfunctions of the transmission of all-wheel drive VAZs. 02.12.04 Photos of faulty units and parts of gearboxes with comments from the foreman have appeared. 11/23/04 Photos of faulty components and parts of the gearboxes of rear-wheel drive VAZs with comments from the technician have appeared. 06.21.03 The content of the paragraph devoted to the conversion of the 4-speed VAZ gearbox into a 5-speed one has been changed.

Speed ​​tables

When driving in a five-speed gearbox, the speeds change slightly and the maximum speed remains the same around 150 km/h. However, the comfort of movement is greatly improved and noise in the cabin is reduced. Speed ​​table with 4-speed gearbox

Speed ​​table with 5-speed gearbox

It is not advisable to spin the ZMZ-402 engine more than 3,000 rpm, because this affects the service life of the motor. Therefore, I highlighted the most comfortable speed in 5th gear with a green quadrangle and in it I placed the speeds for 4th gear at engine speeds of 2,500 and 3,000. Thus, due to the accelerating 5th gear, it is even possible to save fuel.

Selecting transmission oil for manual transmission

SAE 75W-90

Regular transmission inspections ensure safe and comfortable driving. The main factor in maintaining the transmission system in good condition is the use of high-quality oil.

For GAZelle, it is recommended to use gear oil with a viscosity of SAE 75W-90. It provides reliable protection against gearbox wear and corrosion and has good fluidity at low temperatures.

Changing the transmission oil can be done by yourself; it is prescribed at 60,000 km. However, it is possible to carry out this procedure earlier, for example, if you often travel cross-country.

Thus, the GAZelle model 3302 should not be overloaded. A properly functioning gearbox will ensure the normal operation of other vehicle systems. The main reason for expensive mechanical repairs is the driver’s neglect of regular maintenance. Malfunctions with the gearbox also occur due to the fact that low-quality fuel was used. The entire transmission system suffers from this. The problem can be avoided if you constantly monitor the fluid level in the GAZelle 3302 gearbox.

Diagnostics and bearing replacement

To carry out visual diagnostics of the bearing, you need to drain the transmission oil and remove the casing from the gearbox, and dismantle the box itself. Without professional experience, it is better not to do this work yourself, as serious damage to the transmission system can be caused. You can order repair and restoration work from a specialized service.

When disassembling and assembling the box, strict adherence to safety precautions and accuracy is required.

It should be noted that SKF bearings can be installed on the Gazelle. Component parts from this brand are in demand among consumers. The demand is explained by the fact that the offered spare parts withstand temperature effects well. The SKF input shaft bearing has an increased service life, requires virtually no lubrication, and tolerates high rotation speeds well. Thanks to the treatment of their surface, there is a decrease in vibration and noise during their operation.

Thus, the need to replace the primary or secondary shaft of the gearbox arises if they have external damage. These mechanisms should not show any contamination. Since they experience constant loads, gearbox spare parts may prematurely lose their functions. Also, poor lubrication or improper installation can cause premature failure of these mechanisms. A set of gazelle gearbox bearings should be purchased from an official manufacturer, who provides a guarantee for their products.

The comparative cheapness, coupled with the spaciousness of this car, classified as a commercial vehicle, made it a real “workhorse”. It is in demand and is used throughout the CIS. Another sign of a classic work machine is the ease of finding spare parts. When you need to repair a Gazelle gearbox, and the gearbox is the worst of the components of this Russian light-duty car, you can safely go through everything, from bearings to synchronizers. These parts are available for sale at any auto store.

GAZ Gazelle 3302 “Kostya old man” › Logbook › Gearbox repair

Having installed new wheels, we began to deal with the second big problem, namely, difficult gear shifting; upshifting occurred normally, but downshifting was difficult. I suggested to Kostya that he sort through the box himself; first of all, there is no need to pay the service, because... There are big problems with money, then of course I wanted to do it well, but the service department does it too quickly, 4-5 hours for everything, removal, repair and installation, and of course I really enjoyed it myself))). But Kostya was a little freaked out, he still didn’t know me well, and didn’t quite believe that this could be done by the two of us, but he agreed, he liked cost calculations and he also wants to learn how to do independent repairs. First of all, I want to say a big thank you to my father, at my request, he agreed at work to put the car in a pit for the weekend, which we really needed, and his work is located not far from our garages. And so on Friday evening we put the Gazelle in the pit, and while Kostya was driving from work to the garage, my father helped me remove the box and take it to the garage, and there was heat and all the tools. So, Kostya had almost arrived, and while he was still driving, I managed to drain the oil.

It looks like the oil hasn't been changed since the previous gearbox repair.

And so Kostya and I, in a few hours, disassembled and defected all the parts of the box, so that the next morning we could go to the store and buy everything we needed.

This is me, in the process of disassembling the secondary shaft

We bought everything we needed.

Two new forks with nuts, two rings for the couplings, one synchronizer, three bearings and all seals with gaskets (parts missing in the photo)

The washing up

Kostya single-handedly washed all the parts of the gearbox first in gasoline, then a second time in a wax and, of course, the body too. At that time I was doing something else with the car, which I will write a separate blog about later, so as not to mix everything up.

I don’t know how others rearrange the rings on the couplings, I just heard a complete reassembly...

I did it in 2 seconds, squeezed out the inside a little, placed a new ring in alignment and squeezed out all the insides into it.

And here it is assembled, so to speak, a new secondary shaft.

We didn’t have time to take any more photos, because... It was already late and we really wanted to go home. Both bearings on the intermediate shaft were replaced. One came off quite easily, but the second one had to be tinkered with. It was impossible for the puller to catch on to it, and I couldn’t think of anything else how to block the bearing and carefully cut it off with a grinder.

Everything was assembled into a housing, with new seals, with new gaskets, everything was sealed, the reverse sensor was also sealed.

We installed the gearbox back on the car and filled in new oil.

The rocker lever was covered in burrs...

I think it shouldn't be like this...

I carefully polished off all the burrs, generously lubricated everything with saltedol and installed it in place.

The gearshift lever ran all over the cabin, did not hold on at all, it could be removed while driving, hit the passenger, and put back in))). It was customary to make the most reliable and durable way to attach it, a piece of oxygen hose of a suitable size. I won’t describe it, because... The Internet is full of video information about this...

A hose instead of all these plastics and rubber bands and a new casing.

I dressed very tightly and a little not completely, because... It’s winter outside, and the hose is hard, in the summer I’ll put it on all the way...

Breaking

If the manual transmission is noisy, there are reasons for this:

• the bearings performed their functions to the end;
• lack of oil.

The second problem is much easier to solve than the first. Check the amount of oil and “add” it.

We advise you to watch: how to repair a manual transmission on Gezali.

The first option requires replacement of spare parts. This is done either in a service center by specialists (if the car is under warranty, this is a big plus for the owner), or manually (but not by yourself). Only a person who knows the business can disassemble and assemble the checkpoint. This procedure requires knowledge, patience and perseverance.

So, the first thing to do is drain the oil. After this, remove the cardan. Mark the hinge points and the box extension, remove the clamp. Unscrew the cardan mount and remove the shank (move it back and pull it out). The result will be a niche. Next, remove all the necessary parts in the cabin, turn off the speedometer and light elements. After these steps, the box is removed and disconnected.

Gearbox design for Gazelle Next

In order to begin disassembling the gearbox, it needs to be made clean (washed thoroughly). Disassembly is carried out step by step only by a knowledgeable person. At the slightest mistake, the gearbox may not work correctly on the Gazelle Next or, in general, show no signs of life. After disassembling the box into parts, they should also be washed from traces of oil.

The cause of the strange sound is being found. It could be:

• wear of the secondary shaft bearing.
• Bearing play.
• Bearing idling.

Watch the video: how to replace the rear axle gearbox.

Other problems with component parts may also occur. Worn and broken components are replaced with new ones.

Dismantling the box

The gearbox is one of those parts of the car whose repair begins with complete removal. For newcomers to the automotive business, the task may seem titanically difficult, but this is not entirely true. It is enough to thoroughly study the diagram of the box itself (in this case, the gazelle gearbox, consisting of 5 steps) and its connections with the rest of the vehicle in order to understand how to remove it. So, let's begin.

Stages of removing the gearbox from a Gazelle:

1. First of all, you need to drain the oil from the crankcase.
2. Next comes the dismantling of the driveshaft. There is one nuance here: before starting removal, you MUST mark with a file or other tool the locations and directions of the location of the hinge and the box extension. And in general all commutations (rear axle and flanges). Then, we proceed to removing the intermediate support fasteners. You can purchase the set of tools required for this yourself, or they can be included in the standard gearbox repair kit. Next you need to separate the shaft from the main gear flange. Left a little. You need to remove the shank of the box. To do this, you need to slightly pull it back and carefully pull it out. The resulting hole needs to be plugged with some rags or unnecessary old clothes.
3. We take out the gear shift lever. Everything is simple here - remove the cover and the top of the lever from the cab, unlock the bushing and remove the rubber cushion along with the second bushing. All that remains is to remove the seal with the cover and, turning out the cap, remove the lever itself
4. It remains to disconnect the remaining elements from the gearbox - the speedometer and the light switch (reverse). Now you can remove the box itself. To do this, you need to unscrew the receiving pipes and the bracket to the box using the appropriate fasteners. Then we separate our gearbox from the clutch housing by removing the necessary fasteners. But now we will need a medium block of wood, or a small log - this is needed to protect the block head. Now, having removed the transverse fastening, we remove the box itself. Given the significant weight, it is advisable to prepare in advance.

GAZ 3110 | Gear shift

Gear shift and lever position

Manual transmission

The gear shift positions are shown on the handle. Before engaging reverse gear, you must lift the ring under the lever handle.

When changing gears, fully depress the clutch pedal and then release it smoothly. It is not recommended to drive the car with one hand on the gearshift lever, as this increases wear on the gearbox.

When shifting from fifth to fourth gear, do not push the lever laterally to avoid accidentally engaging second gear, which could cause the engine to overspeed and cause engine damage.

Before engaging reverse gear, make sure that the car is at rest and your foot is not on the accelerator pedal. Move the lever from neutral to the right all the way, and then engage reverse.

The table below shows the driving speeds at which you should engage the next gear for maximum fuel economy.

GAZelle cars: gearbox, features and manual transmission repair

The Gazelle model is a small Russian car equipped with a manual transmission (“Gazelle”, “Gazelle-Business”, “Gazelle-Next”). At the same time, the gearbox on this car has its own characteristics that need to be known and taken into account, as well as to operate the unit correctly and to identify and eliminate individual faults in a timely manner.

Let's start with the fact that the five-speed manual transmission of the Gazelle car is reliable, unpretentious in operation and durable. However, since the Gazelle car is primarily a commercial vehicle, the gearbox operates under constant excessive loads, which often leads to its failure.

Let's move on. If we consider the design, malfunctions and repairs of the Gazelle box, it is not structurally a complex mechanism. Main components of the box:

• two aluminum crankcases, which are twisted together with 10 bolts;
• primary and secondary shafts, as well as an intermediate shaft with 1st gear and reverse gear teeth with a pressed-in gear block and speedometer drive gear;
• synchronizers, spring-loaded gear fixation balls, gear lock, gear shift lever damper device;

By the way, as for the GAZelle-Business version, the gearbox in this case is practically no different from analogues on other cars of this model range. The car is equipped with a five-speed three-shaft gearbox with an overdrive fifth gear.

The difference between this box and others installed on Gazelle cars lies in the different gear ratios in all gears. Otherwise, the boxes installed on Gazelle-Business and Gazelle-Next are completely identical.

Main malfunctions of the GAZelle manual transmission

The simplicity of the Gazelle manual transmission design makes it possible to prevent unit failure in the early stages and prevent more severe consequences that can lead to expensive repairs.

Signs of problems with the manual transmission:

To avoid failure of the manual transmission on a Gazelle car, it is necessary to carry out routine diagnostics of the gearbox at least every 30-40 thousand km. mileage The experience of many years of operating Gazelle cars has made it possible to identify the main malfunctions of manual transmissions and their causes:

• hum when the manual transmission is operating - wear of rubbing parts, loosening of fastening bolts;
• crunching in the box - destruction of the bearings;
• crackling sound when shifting gears - wear of synchronizers;
• poor or difficult gear shifting - jamming in the gearbox control drive, gear wear;
• spontaneous gear disengagement (distortion of gear teeth, wear of rods and forks, loosening of the gearbox and driven shaft fastenings);
• decrease in the lubricating fluid level - failure of the crankcase seal, loosening of the tightening bolts, breakdown of the gearbox housing gasket, oil seal leakage, etc.
• It is also necessary to remember that the cause of noise, difficult shifting and spontaneous gear disengagement may be a malfunction in the clutch assembly.

Removal and repair of the GAZelle box

After diagnosing and identifying malfunctions of the manual transmission, you can begin repairs. If you have the necessary qualifications and equipment, you can begin to repair the box yourself.

Main stages of repair work:

• drive the car into a pit, overpass or onto a lift;
• unscrew the mounting bolts and remove the engine and gearbox protection;
• begin dismantling and disassembling the gearbox;

To repair a gearbox, you must have the following tools: a set of keys, a set of screwdrivers, bits, a pry bar, a hammer, etc.

Instructions for dismantling manual transmission:

• drain the oil from the gearbox housing;
• dismantle the cardan shaft;
• put marks on the flanges of the cardan and rear axle;
• remove the fasteners of the intermediate support and cardan to the flange of the main gear drive gear;
• Having pulled the shank out of the box, close the resulting hole;
• get the lever;
• disconnect the speedometer cable and the switch for turning on the reversing lights from the gearbox;
• remove the gearbox from the car;
• Disconnect the gearbox from the clutch housing.

Please note that before assembling the gearbox, it is necessary to inspect the crankcase for defects, the parts must be washed and the rubbing surfaces (bearings, shafts), as well as gaskets, etc. must be inspected. https://www.youtube.com/embed/d90yp3UQQkI

Checkpoint performance test on site.

Raise the rear wheels of the car (jack up and place the rear axle of the car on supports), start the engine and slowly engage the gears one by one (create an imitation of the car’s movement). Test the performance of each transmission for about one minute. WHAT WILL IT GIVE!? Firstly because the gearbox parts have been thoroughly washed, then the initial operation of the gearbox will be dry, despite the fact that the oil has already been filled (oil will not get into all the gaps at once, if you pay attention, only the intermediate shaft is in an oil bath, and it is the oil distributor in the gearbox, in As a result, the operation of the primary and secondary shafts is dry, although where gears and bearings were available, they were lubricated during the assembly process), and when the vehicle is operating without load, it will allow the oil to be painlessly distributed inside the gearbox system, and secondly, in case of unforeseen circumstances (sudden output failure of any element, breakdown, etc.) the operation of components and assemblies will be without load, which will avoid more serious breakdowns.

Active Antenna Feature

An active antenna receives a radio signal and, using a special amplifier, increases its power. The amplifier can be assembled based on semiconductor transistors or more complex microcircuits. The signal applied to the input increases its power due to the DC current applied to it through the amplifier components.

Each active antenna requires additional power supply from a battery. For this purpose, modern car radios have a special positive contact that supplies voltage to the active antenna only when the device is turned on. Despite the fact that the current consumption of the antenna is very small, it must be connected in such a way that it does not work in vain.