Do-it-yourself repair of a VAZ 2107 five-mortar gearbox: disassembly, 10 photos, video

The design of the gearbox of classic domestic cars suffers from low reliability and inability to withstand high loads. Repairing a VAZ 2107 5-speed gearbox is a rather complex procedure that requires a responsible approach and extensive experience. However, if you know the procedure and are technically trained, you can perform the maintenance yourself. As a rule, cars begin to have problems with the inclusion/deceleration of speeds and the loosening of the rocker. With such symptoms, surgical intervention in the structure will be required.

Signs and causes of box malfunctions

Among the most popular reasons for visiting a service station are:

the appearance of specific noise while driving;
extraneous sounds during acceleration;
one or more gears do not engage, it is knocked out.

The symptoms are a clear sign of wear on the gears and synchronizers. Mechanics are often cited as the cause of the breakdown.

Overly aggressive driving. Stock transmissions are not designed for such driving conditions. Acceleration before the cutoff, too high a pace of movement on dirt or low-quality asphalt roads.
Natural wear and tear. Some cars are equipped with a frankly weak transmission. Such devices rarely survive the 200,000 kilometer mark.
Mechanical damage. Impacts against stones and curbs can damage the crankcase of the device, which causes lubricant leaks and dry operation.
Using low-quality oil or neglecting to service the device. If you pour a surrogate lubricant into the gearbox, the reaction can be unpredictable. Similarly, the mechanism responds to the lack of replacement of the working fluid.

VAZ gearbox malfunctions

Gearboxes

On VAZ classics and front-wheel drive VAZ models, the gearbox may fail for various reasons:

There is not enough oil in the crankcase, or there is no oil at all (it has leaked);
the car is operated in violation of the operating rules (for example, the driver switched from fourth gear directly to first gear);
transmission parts have exhausted their service life;
The gearbox repair was carried out in violation of technology and was performed poorly;
The box was repaired using defective, low-quality spare parts.

There are signs that indicate that the manual transmission is faulty:

under load one of the gears slips out (in some cases several gears can slip out);
noise appeared in the gearbox (crunching, howling);
speeds (one or more) have become difficult to switch, in some cases one of the gears does not engage at all;
transmission oil is leaking (the gearbox housing has burst, increased pressure is created in the crankcase, the gasket in the connection has broken).

If the defect is not related to the gearshift lever or linkage, repair of the VAZ manual transmission is carried out with the removal and installation of the unit. To determine the cause of the malfunction, after disassembly, troubleshooting is carried out - by external inspection and measurements, the parts to be replaced are determined.

When and how often should a gearbox be repaired?

The manufacturer does not set a strict time frame for repairing the device. The only recommendation is a scheduled oil change.

The company recommends changing the fluid after 2,000 kilometers for the first time and after 60,000 kilometers for the second time. Further maintenance is limited to maintenance every 20,000-30,000.

Box faults

There are several types of symptoms of breakdown or wear of the VAZ 2107 gearbox.

Lack of response to the inclusion of a position.
The speed takes off at full speed.
Increased noise, howling or grinding coming from inside the mechanism.
The gears are stuck in tightly.
Oil leaked.

The transmission does not start

The reason for the lack of an adequate response to the driver’s manipulations is:

wear of gears and gears;
abrasion of synchronizer bushings;
mechanical damage to the guide bushings;
synchronizer spring wear.

Knocks out gear when driving

The next trouble is the gearshift lever clicking out immediately after engaging the gear.

The reasons are:

the lever joint is jammed;
physical breakdown of the direct lever - the part is changed;
the shift forks in the gearbox are bent;
The clutch is not working properly.

Crunching and grinding in the box while driving

The following breakdown is caused by the following factors:

wear of bearings on shafts;
gear splines are worn out, parts are replaced;

There is not enough oil in the crankcase of the device, it is recommended to add lubricant.

Increased noise

The consequence of the following problems is increased noise emission.

Lack of lubrication in the gearbox housing. The mechanism runs dry, which provokes the appearance of extraneous sounds.
The fluid hasn't been changed for too long. After the lubricant wears out, a large amount of thick ointment consisting of soot, acids, and metal shavings forms inside the mechanism. The mass clogs the channels and oil starvation occurs.
Wear of gear teeth and bearings.

Difficult gear shifting

In this case, you will need to check the clutch - the device may not work correctly. Damage to the basket or disk is also relevant. Separately, the cause may be pouring an excessively thick lubricant or a malfunction of the synchronizer.

Oil leak

Lubricant leakage can be caused by factors.

Mechanical damage to the crankcase when it hits or hits another surface.
Wear of oil seals and seals caused by natural aging of rubber.
Overflow of liquid and, as a result, its displacement from the mechanism.

Possible gearbox malfunctions

Cases in which repair of the Gazelle gearbox is necessary may be as follows:

Changing gears is difficult. In this case, the repair will include the following operations:
the locking bolts may have become loose - they need to be tightened,
Burrs formed on the gear clutch teeth on the inside can also interfere with the normal operation of the unit - accordingly, they need to be cleaned,
If the holes for the pins are broken in the shift lever housing, the lever must be replaced or the stepped pins must be pressed in.
In addition, repair of the gearbox on the Gazelle is also necessary in the case when the gearbox is engaged with a bang, that is, there is a violation in the synchronization of gear engagement. The following points can contribute to this:
deformation of the same ring also indicates the need to replace it. For lapping in this case, you can use a special lapping paste.
Also, box repair is necessary if the gears turn off spontaneously. This malfunction requires the following corrective actions:
it is necessary to replace worn parts, including couplings, if their teeth are worn out,
It may also be necessary to replace the retainer springs if they have become loose.
We can completely eliminate the noise in the Gazelle gearbox with our own hands. To do this you need:
replace damaged gears in case of breakage of their teeth or wear of their working surface,
add oil in the crankcase to the normal level,
restore the alignment of the clutch housing and crankshaft.
When carrying out such operations, you will definitely need knowledge of such an issue as the design of a gearbox. Otherwise, it is not possible to determine the cause of the malfunction (meaning, on your own).
Among other things, manual transmission repair will also be required if an oil leak is detected. The reason for this may be worn oil seals or steel-babbit bushings, or damage to the breather or gaskets, as well as a violation of the tightness of plugs and plugs. In this case, you will also most likely need to change the oil in the gearbox or at least top it up. In any case, repair work must be started by first stocking up with the required amount of liquid.

When carrying out all repair operations, special control is required for the assembly of the gearbox. This problem “disappears” by itself if you contact a car service. By the way, replacing the pins on a Gazelle can be done there.

Diagnostics of box bearings

To check the condition of the gearbox bearings, the device must be disassembled and access to the parts must be opened. This method is the most accurate and effective.

After dismantling and disassembling the unit, you should check the shafts for play, the integrity of the seals and sealing rings. Additionally, the condition of the seats is checked. In normal condition, the formation of backlash and damage to rubber seals is unacceptable. If this is found, the part should be replaced.

VAZ 2107 - we do the gearbox repair ourselves

Gearbox VAZ 2107

Along with the engine and transmission, the gearbox is the main chassis of any car. It’s not worth going on the road without a reliable and properly adjusted gearbox. Every driver knows this, and experienced drivers can even repair it themselves if problems suddenly arise. In this article we will look at, through step-by-step instructions, how to repair the gearbox of a VAZ 2107 car.

Rules for disassembling and assembling the gearbox

If the user has never encountered the repair of such a complex unit, the procedure should be carefully prepared.

Disassembly of the mechanism is carried out only after it has been completely cleaned of dirt.
All the tools required for disassembly are pre-prepared - keys, squeezes, pliers, lock ring pullers. It is also advisable to have a separate container for storing small bolts, nuts, and washers.
It is necessary to dismantle the mechanism parts by first treating the bolts with an anti-boiling agent.
When disassembling, the units are folded in the dismantling sequence.
Human memory is extremely unreliable - a photograph of a disassembled mechanism before its reassembly is the best reminder.
All gaskets without exception must be replaced. Recycling of seals is strictly prohibited.
No one has canceled the abundance of the cleaner. When washing the structure, you should not skimp on the cleaning material; the better you wash it, the more fun it will be.
Assembly of the unit is carried out exclusively in the reverse order.
If after installation there are excess parts left (which is not uncommon), the entire gearbox is completely rebuilt.

It is also necessary to maintain maximum cleanliness during work. Dust, metal shavings, or foreign objects can cause serious damage to the gears.

5-mortar repair

The above procedure involves complete disassembly of the unit as a preventative measure. However, it happens that the manual transmission unit knocks out or slips during driver manipulations. Moreover, the VAZ five-speed transmission suffers from such things all the time. The reason for the repair may be one of the following factors:

the rocker lever gets stuck;
extraneous noise when driving;
one of the gears falls out;
Positions are difficult to switch on.

For a more accurate understanding of the process, you can watch video master classes of the process from experienced specialists.

4th gear slips out

On a five-speed VAZ 2107 gearbox, fifth speed overshoot can provoke wear of the gear, synchronizer, and related parts.
During the repair, the 3/4 clutch, the damaged element and a complete set of seals that are subject to separation during disassembly are replaced.

Note! Some mechanics claim that in 40% of cases, replacing the driveshaft mount and clutch fork saves the day.

5th gear slips out

The five-speed gearbox of the “seven” periodically gives out vagaries to the user due to insufficient gear lubrication. It is recommended that in case of knockout or tight engagement of a position, completely change the synchronizers, gear, fork and bushings - this will ensure stable operation of the unit.

Note! Before purchasing spare parts, it is necessary to troubleshoot them. Some stores sell "crooked" parts.

Repair of gearbox lever (backstage) VAZ 2107

If the gearbox linkage (handle) becomes loose, repairs can be carried out even without removing the unit from the car. However, some experts recommend using “garage” repair parts. For the convenience of the reader and a clearer explanation of the process, it is better to complete the description in pictures.

Dismantle the cover and remove the locking bar from the rocker bushing.

After release, the lever axis is removed; for convenience, you can push the insert with a screwdriver or a pusher.

Usually the bushing itself wears out; you can replace it with a new insert or a standard M10 bolt.

Next, fasten everything in the reverse order and tighten the structure.

Old style gearbox repair

Before repairing an old-type VAZ gearbox, it is advisable to study the user manual or technical documentation. The main nuance is the absence of 5th gear - the classic system has only 4 positions. Therefore, the reverse gear is located separately. This should be taken into account during repairs.

Repair of VAZ 2107 gearbox

Both four-speed and five-speed manual transmissions are installed on Zhiguli Classic cars from the factory - the units are quite reliable and unpretentious to the oil being poured and operating conditions. The “five-speed” disease is the fifth speed slipping, the 5th gear gear is weak and wears out quickly. 4-st. Gearboxes are more durable; they break only at the end of their service life or as a result of barbaric handling.

In order to repair a VAZ 2107 4-speed gearbox, you first need to remove the box. We proceed as follows:

put the car on a pit (lift);
drain the transmission oil from the box;
in the cabin, remove the gear shift lever;
dismantle the driveshaft, disconnect the exhaust pipe of the muffler from the crankcase;
We disconnect the traverse from the bottom of the body;
unscrew the bolts securing the box itself to the internal combustion engine, dismantle the gearbox.

Next, we disassemble the transmission unit:

We pull off the stopper from the shank of the secondary shaft;
Using a 30 mm socket, unscrew the nut and remove the shank;
dismantle the speedometer drive, and then the rear gearbox housing;
disconnect the lower metal tray;
unscrew the nuts of the “bell” (clutch housing), disconnect this casing;
unscrew the nut securing the flush shaft;
remove the stopper from the input shaft;
then we disassemble the rear part of the gearbox - remove the bushing from the secondary one (there is a ball under it, you need to try not to lose it);
disconnect the fork and small reverse gear;
We pull off the stopper from the secondary shaft, and then the large reverse gear;
We remove the retaining ring of the shaft from the back of the housing and pull the gear off the shaft;
unscrew the screws of the metal plate on the back of the case, dismantle the plate;
inside the housing on the rod, unscrew the bolts securing the gear forks;
dismantle the plate, springs and balls fixing the gear shift rods;
we pull out the rods, take out the rear bearing of the shaft;
we pull out the wash basin itself;
Now you can pull out the shafts - “primary” and “secondary”.

We inspect the parts and carry out troubleshooting - install new spare parts, assemble the gearbox.

Replacing bearings

It is impossible to repair the bearings - when they wear out, the non-separable structure changes entirely.

Main shaft bearing

For dismantling you will need:

clamp the input shaft into a yew;
Using a special puller, remove the bearing from its seat.

The removal procedure is accompanied by slight tapping of the part. The installation procedure is performed in reverse order.

Secondary shaft bearing

The only difference between the procedures is the use of different sized bearings.

Replacing the intermediate shaft bearings

The procedure is carried out similarly with the intermediate element. Using yews and a special puller

Replacing oil seals

Structurally, the oil seal is a sealing device that closes the passage to oil. When a part wears out, the housing stops holding liquid and an oil leak occurs.

To dismantle the part, you will need to perform a certain sequence of actions.

Input shaft oil seal

The procedure is performed like this:

completely disassemble the gearbox to open access to the oil seal;
pry off the seal ring with an awl;
remove the oil seal itself from the shaft;
Installation of the new part is carried out in the reverse order.

Secondary shaft oil seal

Disassembling the secondary shaft oil seal is more difficult.

Remove the centering device from the shaft flange.
Use a special puller to pull the flange off the secondary shaft along with the washer;
Use a screwdriver to pry the oil seal out of its socket.
Carefully install the new seal.

Replacing the bearing and oil seal of the secondary shaft of the VAZ 2107 gearbox

The bearing of the secondary shaft ensures free rotation of its end in the place where the shaft already leaves the gearbox. From the inside, the bearing is filled with a lubricant, which facilitates the rotation of the part.

The gearbox secondary shaft oil seal is installed in the same place. The oil seal is a rubber O-ring that fits onto the shaft and fills the gaps between the shaft and the transmission housing. The oil seal is designed to prevent oil leakage and ensures the tightness of the system.

Over time, both the seal and the bearing are subject to natural wear. Parts of the bearing are destroyed and begin to loosen the shaft. Gradually, the friction between the parts increases, and the bearing begins to disrupt the shape of the shaft. The balancing of the shaft becomes unbalanced over time and it begins to vibrate. The very first to suffer is the oil seal, which will lose its shape and will no longer be able to hold oil in the gearbox. The oil gradually disappears and the lubrication of gearbox parts is disrupted. In addition, the oil seal may fail due to wear, which occurs in any case. The fact is that a rubber product has a certain service life, which is determined by mileage and the oil seal begins to crack and also lose its sealing properties.

You can diagnose a seal malfunction visually. To do this, it is enough to look from time to time at the junction of the cardan and the secondary shaft. If traces of transmission oil are found there, then we can confidently say that the oil seal has become unusable and needs to be replaced.

Bearing failure is quite difficult to determine. To do this, you need to have good hearing and know your car perfectly. When driving in gears, a hum and vibration may appear from the gearbox; when the clutch is depressed or the gear is disengaged, the hum disappears, but this sound should not be confused with the sound of a faulty clutch release bearing or gearbox input shaft.

How to replace gears and synchronizers

Initially, it is recommended that if replacement is necessary, contact a car service center. However, if you are confident in your abilities, you can perform the operation yourself. For this you will need:

yews;
special puller;
flat head screwdriver.

Next, the procedure is performed as follows.

Remove the shaft from the gearbox and clamp one side of it into a yew, having previously wrapped it with a soft lining.
Using a screwdriver or awl, remove the retaining rings and all bearings.
Then rest the shaft against the double support and remove the gears from it in direct sequence.

Transmission repair without removing the box

In case of emergency, you can repair the VAZ 5th transmission without removing the housing from the car. When performing the procedure, the car is driven onto an overpass or inspection hole. All manipulations are performed upside down, which complicates the process. Therefore, experienced auto mechanics prefer to first dismantle the unit from the car.

Removing the VAZ 2107 gearbox

To dismantle the VAZ 2107 manual transmission, you must perform the following steps:

Place the machine on an overpass, pit, or lift it onto a lift.
Disconnect ground from the battery. When using a lift, the battery should be disconnected before lifting the machine. Work inside the car also takes place with the lift lowered.
Remove the beard (radio panel).
Press the gearshift lever and use a screwdriver to remove the locking sleeve down from the cavity of the rod (handle).
Remove the gearbox rod (handle) and use tweezers to remove the rubber damper bushing from it.
Use screwdrivers to spread the petals of the damper spacer bushing and remove it, as well as the lower rubber and locking bushings from the lever.
Unscrew the screws securing the cover that covers the hole in the floor of the car in the area where the gearshift lever exits.
Remove the cover and foam seal.
Go into a hole (under an overpass) or lift the car with a lift.
Remove the exhaust pipe.
Unscrew the starter from the clutch housing and move it forward.
Unplug the reverse switch wire.
Disconnect the speedometer drive.
Unscrew the driveshaft from the gearbox and remove it.
Unscrew and remove the clutch slave cylinder from the gearbox housing.
Unscrew the clutch housing mounting bolts.
Place a support under the checkpoint or invite helpers to support it.
Unscrew the 4 gearbox mounting bolts.
Remove the gearbox from the vehicle by moving it to the rear.

After this, you can begin checking and repairing the VAZ 2107 (“5-mortar”) gearbox.

Installation of the box after repair is carried out in the reverse order.