Disassembly and assembly of the gearbox (VAZ-2101)

Before disassembling, the gearbox is washed, installed on a stand, the oil is drained and the bottom cover with the gasket is removed.

Remove the plug 11 (see fig. 60) of the clutch release drive, and from the guide sleeve of the front cover of the gearbox - the clutch 1 assembled with the bearing and the connecting spring. Remove the clutch housing with the gasket and the front cover 56 (see fig. 66) gearbox together with seal 1 and spring washer installed between cover 56 and bearing 2. Unscrew the reversing light switch. Then remove the speedometer drive 38 with the gasket. Having unscrewed the bolt for fastening the fork of shifting III and IV gears, by moving the forks, two gears are engaged simultaneously. This prevents the shafts from turning and allows subsequent disassembly operations to be performed.

Remove the retaining ring 32 from the end of the driven shaft, then, having straightened the retaining washer, unscrew the nut 30 of the elastic coupling flange by several turns in order to move the centering ring 33, and tighten the nut again. Using the ejector A.40006/1 (Fig. 68) with the puller A.40005/4, remove the centering ring and seal 31 (see fig. 66) centering ring of the elastic coupling, unscrew nut 30 and remove the flange of the elastic coupling using puller A.40005/3/9B/9C (Fig. 69).





After this, remove the rear cover of the gearbox by unscrewing screw 2 (Fig. 70) that limits the lateral travel of the lever and moving the shift lever in the direction shown by the arrow to release it from the gear engagement rods.





Remove: from the driven shaft - the rear bearing and the speedometer drive pinion; from the reverse gear engagement rod - a fork with a spacer sleeve; from the axle - intermediate reverse gear; from the intermediate shaft - the retaining ring of the reverse drive pinion, the pinion and the spring washer; from the driven shaft - the retaining ring of the driven reverse gear, pressing the spring washer with the mandrel 41.7816.4069 (Fig. 71) to remove the load from the retaining ring; reverse driven gear and spring washer.



Using shaped mandrels (type of screwdrivers) and rod punches are used to press out the front and rear bearings of the intermediate shaft from the gearbox housing and remove the latter from the housing.


Remove the cover of the locks with the gasket, take out the springs and balls of the locks, and from the crankcase - the reverse gear fork rod and the fork rod of the 3rd and 4th gear shift. Having unscrewed the bolt of the fork of the 1st and 2nd gear shift, take out the rod and the fork of the 1st and 2nd gear shift. While taking out the rods, simultaneously remove three locking (lock) crackers.

Remove the locking plate (Fig. 72) of the intermediate bearing of the driven shaft and the axis of the intermediate reverse gear gear. Take out the shaft together with the bearing and synchronizer ring and remove the needle bearing from the front end of the driven shaft. Knock the driven shaft out of the intermediate bearing, take out the intermediate bearing and remove the driven shaft from the crankcase complete with gears, couplings and synchronizer rings. Then remove the synchronizer coupling of the 3rd and 4th gears from the shaft.



When disassembling the drive shaft, remove the retaining and blocking rings and the synchronizer spring from the rear end; install the shaft on the press and, having compressed the spring washer with the 41.7816.4069 mandrel, remove the front retaining ring, and then the spring washer and bearing.

When disassembling the driven shaft (Fig. 73), remove from the rear side of the shaft gear 22 of the 1st gear with the sleeve and locking ring 19, the hub with the sliding clutch 17 for switching the 1st and 2nd gears, gear 11 of the 2nd gear together with the locking ring 14 of the synchronizer, install the driven shaft with mandrel 41.7816.4069 (4 - Fig. 74) on a press, place support half rings 1 under the gear of the 3rd gear and, pressing with punch 3 through the mandrel onto spring washer 2, remove retaining ring 5 with pliers, then spring washer 2, the hub of the sliding clutch for switching the 3rd and 4th gears and the gear of the 3rd gear.





When disassembling the gearshift lever and the rear cover, remove the cuff 19 (Fig. 75), the boot 21 of the lever with the clamp, then the retaining ring 14, the washer 13, the spring 12 and the spherical washer 11. Unscrew the nuts securing the flange 16, disconnect the release spring 3 of the lever from the eye of the bolt 1 and remove the lever together with the flange, support and cup 5.

Note: Since April 1980, clamp 20 has not been installed.

The gearbox is assembled in the reverse order, taking into account the following:

• the spring of the reverse fork rod retainer differs from others in its elasticity, it is painted green or has a cadmium coating;
• when connecting the clutch housing to the front cover of the gearbox 56 (see fig. 66) the oil drain hole in the front cover should be located at the bottom;
• before installation, coat the working surface of the seals with Litol-24 grease;
• when installing the reverse gear retaining ring, use mandrel 41.7816.4069, and when installing bearings and seals, use mandrel 41.7853.4028; 41.7853.4032; 41.7853.4039.

The specified mandrels are of the same type. Mandrel 41.7853.4039 has an outer punch diameter of 56 mm, on the end of which a centering belt with a diameter of 32.1 mm is made for fitting the gland.

The punch of the 41.7853 mandrel has an outside diameter of 60 mm, and a spring-loaded centering rod with a diameter of 19.5 mm is located in the mandrel tube.

Mandrel punch 41.7853.4028, diameter 74 mm.