Difficulty shifting gears
Depending on the reasons, the gear lever may move with force when engaging all gears or any one pair (I and II or III and IV).
Causes of the malfunction and how to fix it:
- incomplete disengagement of the clutch. How to proceed in this case is described in the section «Clutch»;
- tight movement of the gear selection rod or shift rods in the holes. It is necessary to remove the rods, if necessary, clean the nests of the rods, remove burrs, replace the deformed rods;
- deformation of the linkage of the gear lever. Correct or replace traction;
- loosening or deformation of parts of the gear selection mechanism. In the first case, tighten the bolts of the gear selection mechanism, in the second case, replace the deformed parts;
- synchronizer wear (blocking rings, ends of coupling teeth and synchronizer rims) or damage to synchronizer parts. If the axial clearance between the end face of the blocking ring and the end face of the synchronizer ring gear is 0.6 mm or less, replace the blocking ring. Crushing or chipping at the ends of the teeth of the coupling or the synchronizer crown, as well as other damage that impedes the free movement of the coupling and blocking rings, is not allowed. Replace worn or damaged parts;
- loosening of the clamp fastening the thrust to the gear selection rod or incorrect adjustment of the gear shift actuator. In this case, adjust the shift actuator, and then tighten the clamp bolt nut.
The procedure for adjusting the gear shift actuator:
- acting from the bottom of the vehicle, with loosened clamp bolt 32 (see fig. 62) set the gear selection rod 19 to the neutral position;
- with the decorative cover raised, install the gear lever 38 so that its lower part is perpendicular to the floor of the body, and the lever handle is from the right seat at a distance equal to 1/3 of the distance between the seats. In this position, tighten the clamp nut 32.
Spontaneous disengagement or fuzzy engagement of gears
Causes of the malfunction and how to fix it:
- wear of the balls and rod seats, loss of elasticity or breakage of the springs of the clamps. Replace damaged or worn parts;
- wear of the blocking rings of the synchronizers. Replace blocking rings;
- wear, damage to balls, springs or synchronizer crackers. Replace damaged or worn parts;
- wear of the teeth of the coupling or the ring gear of the synchronizer. Replace clutch or gear;
- deformation of the gear selector lever. Replace lever; wear of plastic bushings in the hinge of the gear selector rod. Replace bushings and damaged protective cover;
- increased vibrations of the power unit on the supports due to cracks or delamination of rubber on the supports. Replace damaged supports;
- non-shifting due to improper adjustment of the gearshift drive. Adjust drive.
Increased noise in the gearbox
Causes of the malfunction and how to fix it:
- wear of gear teeth and synchronizers. Replace worn parts;
- bearing wear. Replace worn or defective bearings;
- insufficient oil level. Restore the oil level to normal, having previously eliminated the causes of oil leakage.
Oil leak
Causes of the malfunction and how to fix it:
- wear of the input shaft seals, axle shafts, speedometer drive or gear selector rod. Determine the location of the leak, replace worn seals;
- loose crankcase or gearbox cover or damaged gaskets. Tighten bolts and nuts, replace gaskets.