VAZ-2109, gearbox: design, causes of breakdowns and repair features

Rice. 3. Gear shift diagram: a – for a four-speed gearbox; b – for a five-speed gearbox

In Fig. Figure 3 shows a shift diagram for a four-speed (a) and five-speed (b) gearbox. To confidently control the gearbox, remember the difference between first and reverse gears. To reverse, engage reverse gear only when the car is completely stopped, pausing for about 3 seconds after pressing the clutch pedal. When selecting reverse gear, the gear shift lever moves from the neutral position in the same direction as for selecting first gear, and then moves with increased resistance all the way to the left and forward to engage the gear.

VAZ-2109 is a fairly popular car in Russia and the CIS. Serial production of the car started in 1987. Over all the years of production, the “nine” was equipped with only two types of boxes. Both were mechanical. Over the years of operation, these gearboxes on the VAZ-2109 caused many problems and complaints among motorists. Well, let's take a closer look at this box and look at its typical problems.

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.

Other differences

there is no additional bushing on the switch;
not the same number of passes;
marking with special paint numbers on the gears of the transmitting elements;
location of ball bearings in crankcase sockets;
This gear is equipped with a synchronizer equipped with a locking ring;
gear 5 of the transmitting element is installed on the spokes of the input shaft;
The shape of the cover on the rear transmission type system is deeper.

Device

This transmission consists of several elements:

Primary and secondary shaft of the VAZ-2109 gearbox.
Transmission box housing.
Synchronizers.
Axles with reverse intermediate gear.
Differential, which changes the gear shift drive.
Aluminum cover with breather. For better heat dissipation, its surface was ribbed.

So, we looked at the design of a typical VAZ-2109 gearbox. This transmission may need to be repaired for several reasons. Below we will look at the main faults and how to fix them.

Repair features

This process is carried out on the box removed from the car. The operation consists of several stages:

Removing the dipstick from the gearbox.
Removing the clutch cable bracket and rear cover.
Unscrewing the fifth-speed fork bolt, as well as the primary and secondary shaft nuts.
Removing the fifth gear gear with the secondary shaft fork and synchronizer.
Removing the thrust plate and bushing from the secondary shaft.
Removing the fifth gear gear.
Unscrewing the screws of the secondary shaft thrust washers and bearing retaining rings.
Removing the plugs, springs and balls of the reverse locks. The process is carried out on an inclined box.
Unscrewing the mounting bolt and 12 nuts of the transmission housing. The element is separated from the clutch housing with a slotted screwdriver.

After disassembling the VAZ-2109 gearbox, you need to replace all worn elements:

Bearings.
Shafts.
Gears.
Gear shift rod.
Seal of axle shafts and shafts.

The VAZ-2109 gearbox is assembled in the reverse order. The crankcase is sitting on the new sealant.

The fundamental principle that the design of the VAZ 2109 gearbox must meet is to achieve an increase in the operational characteristics of the vehicle in conjunction with minimizing fuel consumption. The main tools for implementing these tasks in mechanical transmissions in general, and in the VAZ 2109 manual transmission in particular, are:

Rational selection of the number of gears.

Optimization of gear ratios.

Increase in the quality level of the gear shifting process.

The importance of the latter can hardly be overestimated, since smooth switching guarantees not only a significant increase in the degree of reliability of the vehicle’s systems, components and assemblies, but also a reduction in the driver’s asthenicity (fatigue). The device that ensures smooth shifting is the VAZ 2109 gearbox synchronizer, the diagram of which is presented below.

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.

Advice from experts on manual transmission operation

Like any other complex vehicle mechanism, a manual transmission must be operated in strict compliance with the rules of the vehicle manufacturer. Following these simple rules, as the practice of the Favorit Motors Group of Companies specialists shows, can slow down the wear of parts and reduce the frequency of breakdowns in units.

It is advisable to change gears in accordance with the manufacturers' recommendations regarding the permitted minimum and maximum speeds intended for each gear. In addition, the manufacturer usually provides instructions on how to operate the vehicle economically. For example, for a Volkswagen Polo car (1.6 engine, 110 hp, 5 manual transmission) there are recommendations for economical fuel consumption: switch to second gear at a speed of 20 km/h, to third when reaching 30 km/h, to fourth at 40 km/h and in fifth at 50 km/h.
Shifting into reverse gear (reverse movement) should only be done when the vehicle is completely stationary. Even at low speeds, shifting into reverse gear is unacceptable.
It is recommended to depress the clutch pedal quickly and release it slowly and without jerking. This reduces the friction force on the release bearing and delays the need for repairs.
When driving on a slippery road (ice), you should not drop the clutch or put the gearbox in neutral.
It is not recommended to change gears during sharp turns; this leads to rapid wear of the mechanisms.
Any vehicle needs constant monitoring of the amount of oil in the manual transmission crankcase. If the working fluid is not added and replaced as necessary, the oil becomes saturated with metal dust, which increases wear.

As you can see, it is quite possible to extend the “life” of a manual transmission. To do this, you just need to follow all the manufacturer’s recommendations, and at the first doubt about the quality of work, contact the specialists of Favorit Motors Group of Companies.

The company's technical centers are equipped with all the necessary diagnostic equipment and specialized tools for diagnosing faults and repairing manual transmissions. To perform repair and restoration work, Favorit Motors Group of Companies specialists use technologies recommended by the manufacturer and high-quality certified spare parts.

Auto service technicians have many years of experience and specialized knowledge, which allows them to quickly diagnose faults and carry out any type of repair of manual transmissions. Each specialist regularly undergoes retraining at the training centers of manufacturing plants and receives a certificate for the right to repair and service a certain brand of car.

Customers of the Favorit Motors car service can enjoy convenient work hours, online booking for maintenance and repairs, a flexible loyalty program, a warranty on spare parts and all types of manual transmission repairs. All necessary components and consumables are available at the company’s warehouse.

The price of manual transmission repair depends on the type of breakdown and the amount of repair and restoration work required. By contacting Favorit Motors Group of Companies, you can be sure that the functionality of the “mechanics” will be restored as soon as possible, and the cost of services will not negatively affect the family or corporate budget.

Noise

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.

Noisiness also occurs due to increased loads on the box itself. This happens after tuning the engine (for example, installing “evil” camshafts), which the owners of “nines” love so much. As a result, the engine never drops below three thousand rpm. Both the engine and gearbox suffer wear and tear.

The noise may disappear while driving and appear only when the clutch pedal is pressed. In this case, the box itself has nothing to do with it - the clutch is to blame. It is not the disc itself that is worn out, but the release bearing. Its resource is about 60 thousand kilometers. The element produces a characteristic hum and whistle, which intensifies over time.

Comparison of short and long stroke

Car enthusiasts describe the difference in options as fantastic. The renovation dramatically improves ergonomics. The amplitude of movements of the gear shift knob decreases by two to three times, but the force on its tip increases. The increase is quite acceptable, since gear shifting occurs in an unloaded state with the clutch depressed and does not require any serious effort.

Some experts believe that an increase in the shoulder leads to an increase in forces on the gearbox rods and to additional wear on the gearbox. There is no statistical confirmation of this point of view yet. Unfortunately, it is not possible to order a short-stroke configuration from the factory. You must install it yourself at your own risk. AvtoVAZ does not approve of such changes in the design of the Nine.

Independent modernization of the design associated with welding the levers lengthens them, and the height of the gearshift knob above the tunnel increases by about 5 cm. Such alteration requires welding work and the involvement of an experienced specialist, for whom cutting the levers using a grinder, installing a pipe and a strip of the appropriate section , and also welding the levers is not difficult.

It is difficult or crunching to engage the gear

The problem is a consequence of the failure of synchronizers. The first and second gear synchronizers often wear out. At first, the driver notices difficulties when turning on the desired speed. Then all this begins to be accompanied by a crunch, like on the 53rd LAWN. Do not forcefully press the lever - this will damage the gear block. If there is a problem with the synchronizers, use double squeezing with re-throttle. This is the only way to preserve the gearbox elements while moving to the repair site.

If the box begins to knock when moving, most likely a tooth on the shaft gear or main pair has broken. The element cannot be repaired and must be replaced entirely.

The lever is dangling

If the gearshift lever on a VAZ-2109 is loose, you should check the serviceability of the gearbox hinge (cardan). They have a tapered bolt that can unscrew. In most cases, the problem is solved by tightening it. Note that this bolt is tightly tightened from the factory. It is unscrewed to adjust the scenes.

Backlash also occurs due to a broken return spring, which is located in the gearbox mechanism. It usually changes every 4 years or 100 thousand kilometers.

The cone bolt also unscrews. It is smaller in size than the cardan and is located inside the box itself under the gear shift element.

Reinstalling the gearbox

Gearbox assembly:

we change all non-working elements;
workers clean with a rag;
assembly is carried out;
degrease parts with threads;
if necessary, lubricate the elements;
change gaskets;
insert the balls and bearings into place;
we assemble the synchronizer;
We put all the springs in place and tighten the bolts. When assembling, lubricate all connections with sealant;
attach the box to the engine;
add oil;
connect the battery;
we start the car and check it.

The VAZ 21099 gearbox is adjusted during assembly. Also, after installing the gearbox, you need to adjust the gearshift lever. It is important to adjust the gearbox and gearshift lever correctly.

It should be remembered that prevention can help avoid repairs and troubles along the way. Taking good care of the gearbox is the key to its long-term operation.

Backstage

If the gearbox on a VAZ-2109 is ringing, don’t be upset. All owners of "nines" have this problem. Moreover, the rocker rings both on “killed” and on relatively fresh cars. The AvtoVAZ representative office itself is aware of this defect. And vibration occurs due to the incorrect location of the support points of the internal combustion engine and the gearbox. As a result, the nodes vibrate, and the ringing is transmitted to all other parts, including the slide. Some solve this problem by installing an o-ring in the rocker area, others get used to it and drive like that, with a ringing sound.

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.

Dismantling

To dismantle the box, we recommend that you rely on the instructions, strictly follow the sequence and reinforce your skills with visual videos.

Disconnect the negative terminal from the battery and drain the oil from the gearbox system.
Unscrew the bolts that hold the crankcase guard in place and remove it.
Disconnect the ground (wire) from the clutch housing.
At the end of the clutch cable, loosen the tension on the nuts slightly.
Remove the cable end from the clutch lever.
Disconnect the block from the traction relay.
Disconnect the wire going to the starter traction relay.
Dismantle the starter itself directly.
Disconnect the drive rod from the joint tip. We are talking about traction, which switches gears.
Disconnect the cable from the car's speedometer drive.
Unscrew the tie rod ball joint.
Remove and press the steering rod hinge pin out of the strut swing arm.
The shank of the inner CV joint of the front wheel drive should be pressed out and moved to the side.
Disconnect the second CV joint.
Remove the clutch housing shield.
Release the gearbox from the fasteners holding it to the engine.
Remove the box.

Carefully remove the gearbox
Be sure to move it horizontally away from the engine before directly removing the gearbox. Then disengage the input shaft. Be careful not to damage the clutch spring petals.