VAZ 2101 gearbox: device, do-it-yourself repair

The VAZ 2101 is equipped with a gearbox that differs in operating time. Thanks to it, effective control of the machine is noted. The VAZ 2101 gearbox provides dynamic acceleration.

It should be noted that the VAZ 2106 is equipped with a transmission as standard: 4-speed or 5-mortar. It should be noted that in addition to manual transmission, vehicles may have automatic transmission.

The Zhiguli gearbox is distinguished by its small dimensions. Among the main elements of the device, it is worth highlighting three shafts (primary, secondary, intermediate).

The gearbox input shaft oil seal is distinguished by its compact dimensions. Moreover, it is designed for a long service life. The variable gear ratios of the VAZ 2101 gearbox allow the car to effectively move along the road at different speeds.

Box gears have straight and oblique teeth. There are synchronizer rings, thanks to which the machine is easy to control and speeds can be changed quickly. The box on the VAZ 2101 is connected to the power plant through the clutch.

The transmission includes a linkage that provides connection between the gear shift lever and the rod-shaped rod. The average service life of this spare part is 100,000 km.

The combinations of gear ratios of the VAZ gearbox provide the vehicle with the proper traction at 1 stage and maximum acceleration at 4.

Troubleshooting speed box 2101

Despite the long service life of the high-speed gearbox, this unit requires periodic maintenance and care. Among the causes of device breakdowns when it is necessary to disassemble it, it should be noted - poor gear engagement. In this case, you need to inspect the cylinder and seals. Also, the car owner should check the level of the existing working fluid in the tank. In addition, synchronizers are subject to diagnostics. When they are deformed while the engine is running, changing speed modes occurs with difficulty. The best option is to replace worn parts.

It is advisable to repair the gearbox on a VAZ 2101 if the gear is knocked out. As a rule, this manifestation is due to the fact that the teeth of the gearbox gears have become unusable, the springs and bearings have worn out. Premature deformation of these mechanisms is due to the fact that trips were often made in difficult conditions.

Manifestations such as noise at the 2101 gearbox are a consequence of insufficient oil in the system or the driver uses low quality fuel. Because of this, all components related to the gearbox suffer. Failure of the synchronizer and wear of the clutch basket also contribute to the appearance of noise from the gearbox, and a characteristic crunch may be noted when changing gears.

If any of the above occurs, driving is dangerous. That is why it is worth repairing the VAZ gearbox.

Design features

The VAZ-2101 gearbox diagram shows that the entire assembly consists of three shafts, which are placed in the gearbox housing. Despite the large number of components, the gearbox is relatively compact. Note that this diagram is not complete, since the sliders, latches and shift forks are not visible on it. They are located in the crankcase on the other side of the gearbox.

The input shaft receives torque from the crankshaft. To ensure the possibility of disconnecting the gearbox from the power plant, this connection is not made directly, but through the clutch mechanism. To ensure connection with the driven disk of the clutch mechanism on the first. The shaft is splined.

The primary shaft is fixed on 2 bearings. Moreover, one of them (the front one) is located in the crankshaft, and the gearbox shaft is inserted into it with its end switch. The other is located in the front of the crankcase.

At the second end of the first. The shaft has a gear, and the shaft itself is made integral with it. This gear has a constant clutch with the industrial gear. shaft To prevent oil leakage, the rear bearing of this shaft is covered with an oil seal.

Front end sec. shaft enters the primary. To eliminate axial displacement and maintain their alignment relative to each other, the secondary shaft is mounted on 3 bearings. The front one is of a needle type, installed in the hole in the front end. shaft, where the second limit switch enters. shaft

The second bearing is intermediate, it is a ball bearing and it is installed behind the 1st stage gear. The third is also a ball-shaped one, located on the back of the second. shaft in the crankcase cover.

Below these shafts there is another one - an intermediate one. At the same level with it there is a mechanism that ensures the car moves backwards.

How to remove the gearbox?

Before you begin removing the gearbox (2101) from its original location, it is worth preparing in advance the appropriate tool required for this work. In particular, this is a set of socket wrenches, sockets with extensions of different sizes, screwdrivers, and pliers. Additional materials include rags.

The VAZ gearbox can be removed as follows:

Vehicles must be placed in a viewing hole.
The negative terminal from the battery needs to be removed and the rear exhaust system mount needs to be disconnected.
Using a screwdriver, remove the gearshift lever.
The clamp and the transmission exhaust pipe must be dismantled (fixed with nuts).
The fasteners of the crankcase and clutch are unscrewed, the spring is removed from the fork, and the cotter pin of the pusher axle is removed.
The driveshaft safety bracket, the speedometer cable from the drive, and the elastic coupling must be dismantled.
To remove the coupling, it is advisable to use a special clamp.
It is necessary to unscrew the starter mount to the clutch housing.
Carefully remove the clutch housing cover and the gearbox cross member.

Finally, the box is dismantled along with the clutch. Next, the device must be disassembled. This allows you to determine which components have been worn to the limit and need to be replaced. Corrosion, chips and cracks are unacceptable. For self-repair, a diagram of the box is required. Installation of a 5-speed gearbox on a VAZ should be done in the reverse order.

A little about the principle of operation

The input shaft gear, as well as four industrial gears. shafts are made integral with the shafts. And only on the secondary shaft can the gears move along the shaft. This ensures the possibility of engaging the necessary gears.

Selecting fuel for the transmission system

The manual transmission of the VAZ 2106 is not demanding on fuel. The need to replace the fuel and lubricant arises after the second year of operation. As a rule, oil marked 80W-90 is used. You can change the fuel yourself. To do this, you should arm yourself with a wrench and a hexagon.

It is recommended to check the oil level of gearbox 2101 every 15,000 km. The fuel volume in the crankcase does not exceed 1.4 liters. The fuel needs to be replaced after 40,000 km.

To drain the oil from the gearbox, you need to prepare an empty container, rags, and a hex key in advance. The work is done on a warm engine. The drain plug is unscrewed using a key. Taking this into account, it is necessary to substitute an empty container in advance for draining the transmission. As soon as the liquid has flowed out, the drain plug is screwed in (previously cleaned of settled contaminants). Next, you can begin refueling the gearbox with new fuel. This procedure is carried out using a special syringe or funnel to which an elastic hose is connected.

Instructions for removing, disassembling and assembling the VAZ 2114 gearbox

Removing the gearbox is required when troubleshooting parts and the mechanism of the gearbox itself; when replacing the clutch.

Repair work may require one business day, so the instructions below must be started in the morning. Hiring a partner with experience in this type of repair will reduce time costs and improve the quality of repairs.

Preparation

The preparation process consists of the following steps:

to warm up the oil to be drained, we drive a vehicle for a distance of 5 km;
we install the vehicle on an inspection ditch (pit) or drive it onto an overpass;
We put the car on the handbrake;
raise the hood;
fix the raised hood;
we install the hoist, or use improvised means, or a special device, which is a crossbar to support the engine in a suspended position.

Removing and disassembling the gearbox. Procedure for cleaning gearbox parts

We perform the following steps sequentially:

We remove the terminals.
We remove the battery.
We remove the battery to the side.
We unscrew the three bolts that secure the crankcase protection.
We remove the protection.
If the model is before 2003, then remove the oil level dipstick.
Using a 17 key, unscrew the plug (plug) of the drain hole.
Place a five-liter container under the drain hole.
Drain the existing oil from the gearbox into a container.
We are waiting for the oil to be completely removed from the gearbox.
We unscrew the two locking nuts of the starter protective jacket, located below in relation to the pit, and one locking nut on top of the starter.
Remove the protective jacket of the engine starter.
Disconnect the power wires to the engine starter.
We remove the engine starter from below, that is, by descending into the pit.
Remove the clutch cable.
Compress the spring holding the block.
From below, disconnect the block with the wires of the speed sensor under the hood.
Disconnect the reverse sensor wire connector.
We unscrew the bolts under the hood connecting the ignition module bracket to the gearbox housing.
Disconnect the torque rod bracket.
Loosen the gear shift rod clamps.
We remove it by pulling the torque rod from the hinge intended for changing gears.
We take out the gear shift rod.
Unscrew the fastening bolts to the steering knuckle of the left ball joint.
We carry out dismantling by disconnecting the lower mounting of the gearbox to the engine (sometimes it is enough to loosen the tightening).
Unscrew the bots.
Removing the transmission housing
We unscrew the bot from the lower left part of the gearbox.
Using a board, we hang the motor.
We remove the fixation of the left and rear (attachment to the body) engine mount by unscrewing the corresponding nuts.
We unscrew the pair of bots that secure the rear engine mount to the transmission, holding the nuts against spinning with a second wrench.
We dismantle the support.
We insert a screwdriver into the hole between the engine cylinder block and the clutch housing.
Using an inserted screwdriver, we move the box along the guides so that the rear part of its body passes over the backlight extension, and the input shaft is disconnected from the clutch.
We remove the gearbox unit from under the car.
We clean the gearbox parts, removing deposits with a brush.
We clean the holes and slots from dirt.
We wash and blow off the parts and bearings with a stream of compressed air.
We examine the details of the gearbox.
If necessary, we replace worn or damaged parts.
We carry out the assembly, focusing on the procedure indicated above.

Types of manual transmissions

Based on the number of stages (gears), manual transmissions are mainly divided into:

4-speed;
5-speed;
6-speed.

The most common mechanics is considered to be 5MT, that is, a five-speed gearbox.

Based on the number of shafts, manual transmissions are divided into:

two-shaft, installed on passenger front-wheel drive cars;
three-shaft, installed on rear-wheel drive passenger cars, as well as on trucks.

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Gearbox repair is carried out in case of failure of its constituent elements. Some work is carried out after dismantling the VAZ gearbox. To do this you will need screwdrivers, wrenches, and a jack. Before removing this unit, it is necessary to drive the vehicle onto an inspection hole or overpass.

From 4-speed to 5-speed

Finally, let’s consider such an issue as converting the gearbox from 4 to 5 stages of the VAZ-2105. Such a modification is quite possible, since when the five-speed gearbox was created, the basis for it was the 4-speed version. But in this case, you will have to replace some of the components taken from the 5-speed gearbox, namely:

Back cover;
Intermediate shaft (with a hole for mounting the 5th gear gear block);
Secondary shaft (in the 5-speed version it is slightly shorter);
5th speed gear block;
Reverse idler gear axis;
A set of rods together with a fork for 5th and reverse gears;
Gear shift mechanism (slide);
Reverse light sensor;
Power unit mounting bracket;

Next, it is enough to completely disassemble the 4-speed gearbox and assemble it as a 5-speed gearbox using the specified components.

Possible malfunctions of the machine

Foreign-made cars most often suffer from breakdowns, and it is not always worth starting to repair them yourself. This can lead to numerous problems in the event of further contact with car service centers of this manufacturer, so you will have to answer this question yourself, taking into account your skills and capabilities.

With an automatic machine, most often:

The electronic control unit fails, which causes problems with the process of switching not only “upper” but also “lower” gears. Often they may stop switching speeds from 1 to 4.
Troubles can begin due to violation of the rules of car operation: if you braked sharply, tried to quickly change gears, or put the car in reverse when the car was not completely stopped.
Cars with automatic transmission are extremely demanding on the quality and quantity of oil that you pour into it. If there is constant overfilling or underfilling, malfunctions may occur and the gearbox will need to be repaired.

All car owners know that manual transmissions are much easier to repair than automatic ones. Before you start repairing the machine, you should think several times and listen to the opinion of the experts at the service center. Many parts are expensive, not only new ones, but also used ones. And the center’s technicians may refuse to complete the repair work if they see that someone has been “digging” in the car before them. Therefore, the decision is up to you.