Disassembly and assembly of the gearbox (VAZ-21213)

Disassembly

Wash the gearbox and install it on the stand. Drain the oil and remove the lower cover with the gasket.

Remove the clutch release fork and, from the guide sleeve of the front gearbox cover, the clutch assembly with the bearing and connecting spring.

Remove the clutch housing with the gasket and the front cover of the gearbox together with the oil seal and spring washer (Fig. 3-15).



Unscrew the reversing light switch, being careful not to deform its housing.

Remove the bolt securing the shift fork for the third and fourth gears. Install the locking pin 41.7816.4068 on the primary shaft or engage two gears simultaneously. This will prevent the primary, secondary and intermediate shafts from turning and will allow subsequent disassembly operations to be performed.

Note: Since 1997, the following parts have been redesigned at the rear end of the transmission secondary shaft:

• instead of the metal centering ring 26 (Fig. 3-31) and the retaining ring, a rubber centering sleeve is installed;
• instead of seal 25 with spring 24, a seal without a spring is installed;
• lock washer 22 replaced with spring washer;
• nut 23 is installed on sealant UG-9 or UG-10.

Remove the retaining ring from the end of the transmission secondary shaft (Fig. 3-16).



After straightening the lock washer, unscrew the nut a few turns to move the centering ring of the elastic coupling, and tighten the nut again. Using the ejector A.40006/1 with the puller A.40005/4, remove the centering ring of the elastic coupling of the cardan shaft from the end of the secondary shaft (Fig. 3-17).



Remove the seal of the centering ring of the elastic coupling with the spring from the end of the secondary shaft, unscrew the nut and remove the flange of the elastic coupling using the A.40005/3/9B/9C puller (Fig. 3-18).




Before removing the rear cover, set the gearshift lever to neutral, unscrew the gear selector mechanism mounting nuts and remove the gearshift lever (Fig. 3-19) assembled with the selector mechanism. One of the cover mounting nuts is unscrewed from inside the gearbox housing with the lower cover removed. When removing the rear cover, it must not only be fed back, but also turned to prevent it from touching the reverse gear block and 5th gear.



After removing the inner ring of the rear bearing 43 from the secondary shaft (fig. 3-12) and the spacer sleeve 44 of the bearing, loosen the cover mounting bolts 5 (Fig. 3-20) and unscrew the bolts 2 and 4 of the gear block and the fork for engaging the 5th gear and reverse gear. Remove the oil deflector washer 45 fig. 3-12), and then sleeve 1 (Fig. 3-21) of the fifth gear and remove rod 1 (Fig. 3-22) from fork 2. At the same time, spacer sleeve 3 is removed from the rod. Then remove gear block 4 from the splines of the intermediate shaft.







Remove the intermediate gear 1 (Fig. 3-23) of the reverse gear from the axle, gear 3 assembled with the clutch and fork 4 from the secondary shaft at the same time.



Using shaped mandrels (type of screwdrivers) remove the hub 4 (Fig. 3-24) of the 5th gear synchronizer and the driven gear 2 of the reverse gear from the key.



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Using shaped mandrels (type of screwdrivers) and rod punches, remove the front and rear bearings of the intermediate shaft from the gearbox housing. On the inner rings of the double-row bearing, apply marks according to which these rings are installed in their previous places in the outer ring of the bearing.

Remove the intermediate shaft from the gearbox housing by tilting it as shown in Fig. 3-25.



Remove the shift fork rods of the 1st, 2nd, 3rd and 4th gears from the gearbox housing one by one, after first unscrewing the fork mounting bolts. While removing the rods, simultaneously remove the three locking crackers 6 (Fig. 3-26). Remove the locking plate (Fig. 3-27) of the secondary shaft intermediate bearing. Unscrew the reverse intermediate gear axle mounting nut and remove it.





Using mandrels (type of screwdrivers) remove the primary shaft together with the bearing and synchronizer ring (Fig. 3-28) and remove the needle bearing from the front end of the secondary shaft.



Knock out the secondary shaft from the intermediate bearing, remove the intermediate bearing and, tilting it as shown in Fig. 3-29, remove the secondary shaft from the crankcase complete with gears, couplings and synchronizer rings. Remove the III and IV gear synchronizer coupling from the shaft.



Disassemble the primary shaft (Fig. 3-30), for which:

• remove the retaining ring 7, the locking ring 6 and the synchronizer spring 5;
• install the shaft on the press and, having compressed the spring washer 2 with the mandrel 41.7816.4069, remove the retaining ring 1, and then the spring washer and bearing 3.

Disassemble the secondary shaft (Fig. 3-31):

• remove gear 11 of the first gear with sleeve 12, hub 3 with sliding clutch 4 for switching 1st and 2nd gears, gear 10 of the second gear together with locking ring 5 of the synchronizer from the rear side of the shaft;
• install the secondary shaft with mandrel 41.7816.4069 on the press (Fig. 3-32), place support half rings 3 under the third gear pinion and, pressing the mandrel on the spring washer, remove the retaining ring 2, then the spring washer 4, the hub of the sliding clutch for switching third and fourth gears and the third gear pinion.

If necessary, disassemble the lever and gear selection mechanism, for which:

• remove protective cover 10 (Fig. 3-33), retaining and thrust rings 6 and 7, spring 5 and spherical washer 4 from the gear shift lever;
• visually mark the position of the parts relative to mark A (Fig. 3-34) applied to the guide plate so that during assembly the parts are connected in the same position;
• after unscrewing the nuts from the mounting bolts, separate the parts of the gear selection mechanism and remove the lever 9, its ball joint 4 and rubber sealing rings 15.

Assembly

Assemble the gearbox in the reverse order of disassembly. Please note that:

• the reverse intermediate gear shaft is secured before installing the shafts in the gearbox housing with a torque of 78 N·m (7.8 kgf·m);
• before installing the V gear and reverse gear fork rod into the crankcase, install a spacer sleeve on it;
• the inner ring of the bearing is pressed onto the block of gears of the 5th gear and reverse gear, and the outer ring is pressed into the socket of the rear cover;
• the secondary shaft rear bearing is pressed onto the shaft to facilitate installation of the rear cover;
• install intermediate gear 1 (Fig. 3-23) of reverse gear, gear 3 and fork 4 simultaneously;
• when assembling the gear shift lever, coat the ball head or ball joint sphere with LSC-15 or Litol-24 grease;
• tighten the gear block mounting bolt to a torque of 78 N·m (7.8 kgf·m);
• when installing the clutch housing with the front cover of the gearbox, the hole in the front cover must be positioned as shown in Fig. 3-15;
• before installation, coat the working surface of the seals with Litol-24 grease;
• when installing seals and bearings, use mandrels 41.7853.4028, 41.7853.4032, 41.7853.4039.