Gear ratios of the gearbox
Table 6.1.
| Broadcast | Gear ratio |
| I | 3,727 |
| II | 2,043 |
| III | 1,393 |
| IV | 1,029 |
| V | 0,795 |
| Reverse | 3,545 |
| Home | 4,214 |
Possible malfunctions of a manual gearbox, their causes and methods of elimination
| Cause of malfunction | Method of elimination |
| Vibration, noise in the gearbox | |
| Loose or damaged engine and gearbox mounts | Tighten the fasteners or replace the supports |
| Wear or damage to gears and bearings | Repair the gearbox at the service center |
| The wrong grade of oil was poured in | Fill with the required grade of oil |
| Insufficient oil level | Top up the oil to the required level |
| Engine idle speed adjustment malfunction | Adjust engine idle speed |
| Oil leak | |
| Destruction or damage of seals or O-rings | Replace seals or o-rings |
| Difficulty shifting gears and grinding noise when shifting | |
| Incomplete clutch disengagement | Repair the clutch drive |
| Loose or worn locking rings and synchronizer cones | Repair the gearbox at the service center |
| Weakening the synchronizer springs | Repair the gearbox at the service center |
| The wrong grade of oil was poured in | Fill with the required grade of oil |
| Spontaneous gear disengagement | |
| Wear of gear shift forks or breakage of detent springs | Repair the gearbox at the service center |
| Increased clearance of the synchronizer clutch on the hub | Same |
The identification data of the gearbox is stamped on the lower part of its housing (Fig. 6.4).
The manual gearbox is made according to a two-shaft scheme with five synchronized forward gears. The gearbox and the main gear with the differential have a common housing. The clutch housing is attached to the front part of the gearbox housing. A stamped steel cover is installed on the rear part of the gearbox housing.
The primary shaft contains a 5th gear pinion with a synchronizer rotating on a needle bearing, and the drive pinions of the 1st, 2nd, 3rd and 4th gears are made as a single unit with the primary shaft.
The secondary shaft is made together with the driving gear of the main transmission; in addition, freely rotating driven gears of the 1st, 2nd, 3rd and 4th gears are installed on the shaft, as well as the driven gear of the 5th gear fixed on the shaft splines.
Forward gears are engaged by axial movement of the clutches of two synchronizers of I-II and III-IV gears, installed on the secondary shaft, and the clutch of the synchronizer of V gear, installed on the primary shaft. Gear shift mechanism 11 (see fig. 6.3) located in the cover installed on top of the 3 gearbox housing.
The manual gearbox control drive consists of a linkage 5 (Fig. 6.5), a gearshift lever 3 with a ball joint secured to the body base with nuts 4, a rod 2 for the gearbox control drive and a mechanism 11 (see fig. 6.3), mounted on the gearbox housing.
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The main transmission is made in the form of a pair of cylindrical gears, selected for noise. Torque is transmitted from the driven gear of the main transmission to the differential and then to the front wheel drives.
The differential is bevel, with two satellites. The tightness of the connection of the inner joint of the right front wheel drive with the differential gear is ensured by a seal pressed into the gearbox housing, and the inner joint of the left drive is ensured by a seal installed in the joint boot. The boot of the inner joint of the left drive is fixedly secured by a special holder on the gearbox housing, and the drive shaft rotates inside the boot on a ball bearing.
At the bottom of the manual gearbox housing there is a drain plug, and on the side there is a plug 2 (see fig. 6.3) filling hole.
Gearbox repair requires a large set of special tools and appropriate training of the performer, so this section only covers the removal and installation of the gearbox, replacement of its seals and repair of the drive. If you need to repair the gearbox, contact a specialized service.
The procedure for changing the oil in the gearbox is described further in the subsection "Checking the level and adding oil to a manual gearbox".
Fig. 6.3. Manual gearbox: 1 - clutch release fork; 2 - filler plug; 3 - gearbox housing; 4 - back cover; 5 - Reverse light switch; 6 - clutch housing; 7 - speed sensor; 8 - gearbox control lever; 9 - gear selection rod; 10 - gear shift lever; 11 - gear shift mechanism; 12 - breather.
Fig. 6.4. Gearbox identification data: 1 - gearbox type; 2 - gearbox modification; 3 - gearbox serial number; 4 - manufacturer's code.
Fig. 6.5. Manual transmission control drive: 1 - gearbox control drive rod mounting clamp; 2 - gearbox control drive rod; 3 - gearbox control lever; 4.6 - nuts; 5 - gearbox control lever linkage; 7 - washer.