Features of replacing the clutch cable on a Lada Kalina car

02/28/2022 10 171 VAZ Kalina

Author: Ivan Baranov

The clutch cable (TC) is one of the most important elements of the car, thanks to which the clutch operates. Its malfunction can seriously affect the operation of the clutch mechanism and even lead to a complete stop of the car and the impossibility of further movement. The article provides detailed instructions for replacing the clutch cable on a Lada Kalina.

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Why do you need a clutch cable and when to change it?

Thanks to the clutch, torque is transmitted from the transmission to the power unit. The gearbox is connected to the engine by a vehicle, which is a metal cable. It is with the help of the vehicle that the car starts, gears are changed and braking is carried out. Thanks to this lever mechanism, the car moves.

Lada Kalina is equipped with a ratcheting mechanism, thanks to which the length of the cable is adjusted. During clutch operation, the friction linings of the disc are constantly worn out, and the tension of the vehicle changes. The tension is adjusted using a ratchet mechanism.

In theory, the ratchet mechanism works as follows:

• due to the tension of the cable, the clutch release fork (VVS) rotates, causing the spring to compress;
• when compressed, the spring causes compression of the clamps located on the tip of the vehicle;
• Thus, the tip is released, the vehicle is tensioned.

In reality, drivers often have to make frequent manual adjustments.

Clutch cable and adjustment mechanism

Signs that your vehicle needs adjustment or replacement:

• the appearance of extraneous sounds when the clutch is disengaged;
• gears shift poorly;
• insufficient traction;
• the clutch does not disengage completely;
• The clutch pedal (PS) has failed.

Before you start adjusting the vehicle on the Lada Kalina, you should check its condition. The vehicle requires replacement if it is rusty, torn or has any damage. To check the condition of the vehicle, it is necessary to remove the air filter.

What does incorrect adjustment of the Kalina clutch lead to?

If the gaps are not set correctly, the auto compensator may not work correctly, or may not work at all if the gap under the hood is too low (10mm or less). The release bearing may also howl.

For example, my release bearing was humming in 4th and 5th gears. After adjusting the clutch cable , the noise disappeared. Many questions also arise about the fact that the clutch “takes over” at the very end. This is, in principle, normal. Structurally, the clutch on Kalina begins to grab in the second half of the stroke. Therefore, setting it up to start the stroke means making constructive changes to its operation, which is not desirable.

Replacement process

If defects in the vehicle are detected, or if it breaks, it must be replaced.

Required Tools

To carry out work, the car is installed in a convenient position.

To replace the vehicle you will need a few tools:

• new cable;
• ruler or caliper;
• key to "8";
• screwdriver.

New vehicle for Kalina
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Stages

The procedure for replacing a vehicle on a Lada Kalina consists of three stages: removal, installation and adjustment.

Removing the vehicle:

1. Work begins on the car interior. First you need to remove the vehicle shell stopper. To do this, you need to find the fastening nut for the support of the vehicle shell to the PS bracket under the tool panel and unscrew it with a key “8”. The stop can then be removed from the stud.
2. Next, use a flat screwdriver to pry and remove the spring clip from the PS groove.
3. Then you need to remove the eye of the ratchet mechanism that regulates the tension of the vehicle.
4. It is necessary to remove the plastic sleeve from the PS finger and make a visual inspection of it. If it is worn or damaged, it should be replaced.

   
   Checking the condition of the plastic bushing
   Before installing the bushing in place, it must be lubricated with Litol-24 or LSC-15.

5. Work then continues in the engine compartment.
6. In order to get to the vehicle, you need to remove the air filter.
7. Next, you should pull the cable by the tip and pull the leash out of the groove of the vehicle lever.
8. Having unscrewed the leash from the threaded end of the cable, remove the leash.
9. Then you need to remove the protective rubber cover from the tip of the vehicle.
10. Next, you need to remove the lower tip of the vehicle from the bracket, which is installed on the gearbox housing.
11. Having moved back into the cabin, we remove the upper part of the vehicle from the pedal assembly bracket.
12. Having pulled out the vehicle sealing cover from the hole in the front panel, remove the cable.

    
    Pull the cable into the cabin

Vehicle installation:

1. The vehicle should be passed through the hole in the front panel from the passenger compartment into the engine compartment.
2. Next, you need to put the ratchet mechanism for adjusting the tension of the vehicle onto the PS finger and secure it with a fixing bracket.
3. Then you need to secure the vehicle shell bracket to the PS bracket using a nut.
4. Now the vehicle sealing cover is installed in the opening of the front end.
5. Next, having passed the vehicle through the hole in the gearbox bracket, install the guide sleeve of the vehicle shell into this hole.
6. Now you need to screw a plastic leash onto the lower tip of the vehicle so that the tip protrudes relative to the end no more than 1 mm; flush would be ideal.
7. Next, we insert the leash into the groove of the Air Force lever.

Adjusting the vehicle on the Lada Kalina:

To adjust the clutch, it is necessary, overcoming the force of the PS spring, to pull the vehicle by the threaded tip forward along the movement of the vehicle until it stops and hold it in this position.

1. It is necessary to measure the distance from the end of the plastic tip to the air force lever using a ruler or caliper; it should be 27 mm.

   
   We measure the distance from the leash to the fork

2. If the distance does not match, then it must be adjusted by rotating the leash in the desired direction.
3. Next, you need to insert the tip of the vehicle into the groove of the VVS lever and release it. Thanks to the spring, the tip should fit without any gap.

   
   Example of correct and incorrect adjustment

4. Next, you need to press the PS several times until it stops so that the automatic mechanism for adjusting the length of the vehicle works. The full pedal stroke on the Lada Kalina should not exceed 146 mm.

Thus, replacing a vehicle with a Lada Kalina is a simple procedure that even a novice driver can perform. By learning how to change the cable yourself, you can save on a car service and replace it if it breaks on the road.

In order to avoid troubles with a vehicle breakage on the road, you should always carry a spare one in the glove compartment. If the vehicle breaks down on the road, this will not lead to problems; you can always replace the broken cable with a new one.

Step by step guide

To replace the clutch cable on a Lada Kalina, you need to prepare some spare parts and tools, namely: a new clutch cable, a figure eight wrench, a regular ruler, a rag, a flat screwdriver and a caliper.

1. The first thing to do is to pick up the prepared eight-point wrench and unscrew the nut that secures the cable. You will find it on the clutch pedal in the car. This nut serves as a stop for the cable sheath into the bracket.
2. Using a flathead screwdriver, remove the retaining clip very carefully. It is located directly under the nut.
3. The next step is to remove the housing of the mechanism that regulates the cable, in order to pull out the cable by removing it from its attachment to the pedal.
4. The cable itself is located behind the filter; it needs to be removed. To do this, pull up the clutch lever and calmly pull out the cable.

Now it's time to get to work in the engine compartment of the Lada Kalina.

1. Open the hood and immediately pull out the cable from the fork-shaped fastening, simply pull it towards you.
2. Now we unscrew the plastic leash; you can do this without tools, with your own hands.
3. You will see a rubber cover at the end of the cable; this will also have to be removed.
4. Now you need to disconnect the end of the cable from the holder located on the box

Dismantling the old cable

1. First, we find the clutch drive pedal.
2. We remove the stop from the cable sheath. The braid itself is attached to the pedal bracket. The manipulation is very simple. Using the “8” wrench, we simply unscrew the nut that secures the shell to the bracket. Having “defeated” the nut, we easily remove the stop from the stud.
3. Now there is an approach directly to the finger. A stopper is held on it, which we remove using pliers (or a screwdriver). After dismantling the marked stopper, remove the clutch disc compensation unit (driven).
4. We remove the plastic bushing located on the pedal drive finger. A visual inspection of its condition would be useful. If there are visible deformations, we replace it with a new product. Before installing the bushing, lubricate the pin surface with lithol.
5. We proceed to removing the seal from the cable sheath.

In the interior of the Lada Kalina, the entire list of manipulations has been completed, so the next step will be dismantling the elements under the hood.

Let's proceed further

1. On the transmission unit, pull the end of the cable towards you. It should come out of the landing hook without any effort.
2. Now we unscrew the leash, which we remove from the tip.
3. The final step is to pull the clutch cable out of the bracket on the transmission.

A special feature of the Lada Kalina model is its one-piece bracket, not a split one. Here you will need to remove the cable from the corresponding hole in the bracket towards the interior. The component we are looking at is now removed.

When adjustment is required

Clutch adjustment is only performed when the engine is switched off. It is required if there is a deviation from the following values:

• full pedal travel does not exceed 146 mm;
• movement of the cable lead relative to the release fork lever - within 270 mm;
• runout of the dependent disc linings does not exceed 0.5 mm;
• the distance between the pads and the rivets that hold them is 0.2 mm or less.

There are several ways to check if your car needs a clutch adjustment.

• You should press the pedal several times in a row and listen for any extraneous noise. If the clutch pedal sticks or squeaks, it is advisable to make an adjustment. In some cases, car owners are unable to visually assess whether the pedal returns to its place freely. In such situations, it is recommended to do the following:

• press the clutch with your hand until it stops;
• stop applying force, but leave your hand on the pedal in order to feel if there is movement.

Without noise and dust: how to properly adjust the clutch on a Kalina station wagon yourself?

You should start working no earlier than the engine has completely cooled down. The setup method is simple and does not require a visit to a car service center, because you can do everything yourself. The step-by-step scheme for completing the work is as follows:

• Before adjusting the clutch drive on Kalina, you should open the engine compartment hood and remove the air filter.
• Visually assess the condition of the cable casing and replace it if damaged.
• Pull the tip toward you until the cable is fully tensioned. After this, check the distance between the fork and the leash with a caliper.
• If the measurements show more than 27 mm, then the distance is corrected by rotating the leader along the thread of the tip.
• Press and release the clutch pedal several times and repeat the measurements.
• If necessary, repeat the adjustment until the required standards are achieved.

The procedure for adjusting the clutch on Kalina

Owners of Lada cars who have discovered faults in their vehicles are interested in how to adjust the clutch. To do this you need to perform a number of steps.

1. Pull the cable forward until it stops at the threaded end. In this case, it is necessary to overcome the resistance of the spring attached to the clutch pedal.
2. While holding the cable, use a caliper to measure the distance from the plastic leash to the clutch release fork lever.
3. By rotating the leash, bring the distance to the required values. Make sure that when releasing the cable, the leash fits tightly to the fork lever.
4. Press the clutch pedal three times to activate the automatic cable length adjustment system.
5. Check the full pedal travel.

Adjusting the clutch on a Kalina car is a procedure that every owner of this car must master. By performing timely adjustments, you can significantly extend the life of your vehicle.

And so I changed the clutch cable, the question arose, how to adjust?! I looked through the manual, I have two of them! ?! no matter how I twist it, it doesn’t work, the stone flower means the required gap

through simple mathematical calculations. 40- (27+12) = 1 mm, does it seem so? and where to turn it?

Clutch faults Lada Kalina

Long-term use leaves its mark on the clutch mechanism; the driven disc linings wear out and become thinner. In order to compensate for this wear, the ratchet mechanism, as we have already said, automatically compensates for the degree of wear and tightens the cable. This is done by turning the release fork, causing the spring, which is located in the bushing of the adjustment mechanism, to compress. The spring, in turn, compresses the clamps of the toothed tip of the cable, after which the tip is released and tightens the cable.

Installation of a new cable

We carry out the installation procedure following this algorithm. We start with manipulations in the salon.

1. First of all, we thread the cable into the engine compartment.
2. Now we install the body of the compensation mechanism, which serves to level out wear on the disc linings. We install the body itself on the finger and secure it with a locking bracket.
3. We return the cable sheath seal to its place.
4. In the engine compartment we pass the cable through the bracket, after which we install the guide sleeve.
5. We screw the leash onto the lower tip of the component. Tightening should be done so as to provide the tip with a protrusion of approximately 1 mm.
6. Now we pull the cable all the way. When this manipulation is completely completed, we measure the adjustment distance using a caliper. In optimal condition it should be 27 mm. When the measurements give a different value, we rotate the leash and achieve the specified indicator.
7. We place a cable end in the groove on the clutch fork. Under the pressure of the spring, the leash will “climb” into the fork.
8. By pressing the pedal several times, we check the unhindered functionality of the unit. We immediately control the adjustment gap (27 mm).

Adjusting the pedal position

Having completed replacing the cable in LADA Kalina, it will be useful to adjust the pedal assembly. For this purpose, you will need to place the car on a level area. Now we measure the pedal stroke. We use a ruler. We apply it to the floor and the starting point of the pedal. We press and measure. The stroke should be no more than 150 mm. If the fact of excess is evident, then we adjust the position.

To make adjustments, move to the engine compartment. Here, at the junction of the fork and the cable, there are two adjusting nuts. We twist the first one (the locking one), after which we rotate the second one until the required stroke is achieved. Typically this value is 120-130 mm. Continuing to loosen the nut, we increase the free play, and do the opposite - we decrease it.