The article describes how to repair the checkpoint in the VAZ 2108. All items, details and nuances.
VAZ 2108 - Gearbox: device components, its repair and improvement
The domestic car is a car with front-wheel drive, and the engine is placed transversely, used to move along the tracks. The metal body is made in accordance with the type of hatchback, which has 3 doors. The rear door is designed for loading and unloading luggage. During transportation of long and oversized baggage, the back row is folded - this moment increases the luggage compartment.
4-cylinder carburetor engines with a volume of 1.1, 1.3 or 1.5 liters. At the moment, fuel injection systems are installed in some cars. The front-wheel drive car guarantees improved controllability of the car when cornering, even during wet roads. During long-term use of the car, many elements wear out, the fasteners of the unit assemblies are loosened and adjustable values are violated.
The gearbox is the most reliable element in the car. Failure of this mechanism is quite rare, compared with other parts. And with all this, its complete or partial failure makes it completely unsuitable for further use of the car. It will simply be impossible to operate the car for its intended purpose. In addition, a tow truck will be required to deliver the car for gearbox repair.
The prevailing types of breakdowns
One of the types of damage to the checkpoint on the VAZ 2108 Bearing wear or oil shortage in the gear shift assembly is considered. And with all this damage is very easy to fix, by changing the oil or changing the bearings. Quite another, if we are talking about more serious breakdowns associated with axial rearrangement of shafts, curvature of the gear knob, seizing, unreasonably engaging, disengaging gears, deterioration of fasteners, various nuts, as well as springs by impairing the flexibility of the balls - in such situations without proper repair, get along.
Design and further repair of the gearbox
Repair of the VAZ 2108 checkpoint is a very complex and time-consuming process, in addition, if the car has sufficient mileage. Despite multiple service stations, not all specialists will be able to make repairs. There can be many reasons for this. For example, little experience, as well as the lack of spare parts in stock. PPC - is considered a complex element of the car. She is able to change the traction force of the driving wheels of the car due to the engagement of gears with different numbers of teeth.
In addition, it provides reverse gear and a long separation of the motor (together with the clutch) with other transmission elements, while the car is standing or moving by inertia. Engagement of gears with different numbers of teeth is realized by their movement. The drive shaft is connected to the drive clutch, while the drive shaft with other transmission elements.
The drawn shaft in relation to the main one is able to rotate with a different number of revolutions. The adapter shaft with a fixed set of gears through them is in constant engagement with the main shaft.
Gearbox disassembly
In some cases, this happens - the box breaks, and the apparent reason is not immediately established. To identify it, the checkpoint should be dismantled. Not everyone and not always can immediately get to the service station, and you have to do the removal of the box yourself. For safety, it must be disassembled together, as some parts with significant mass in the event of a fall can injure a person.
First, remove the + terminal from the battery, and drain the liquid from the box. After this procedure, remove the pallet guard. There is a wire on the crankcase called a “mass” attached by a bolt. This wire should be removed and slightly pushed to the side so that it does not tear, during subsequent disassembly at the VAZ 2108 gearbox. First, take out the clutch cable. After we separate the block with the starter relay. Remove 3 bolts and disconnect starter. Then we go under the car. Loosen the clamp and unhook the joint from the gear shift rod. Unscrew the cable for the speedometer drive and the wiring for turning on the rear speed lamp.
Then you need to unscrew the nuts located on the suspension arm. Unscrew the whole nut that connects the bracket and the extension. Next - turn the braces to the sides so that they do not interfere to continue disassembling. The cotter pin of the nut itself, which is responsible for securing the ball joint to the rotation handle, should be unscrewed and pulled out. The tie rod assembly nuts must also be loosened.
Next - knock the ball finger out of the turn handle. Then we unscrew 2 bolts and disconnect the ball with the fist of rotation. From the 1st of the CV joints of the drive wheels, the shank should be knocked out. Here you need a mount. One CV joint was released, and the second should be released.
Then remove the crankcase cover. The tightening, located between it and the cylinder block, which is mounted on 3 bolts, should be loosened. Therefore, after removing the VAZ 2108 5-speed gearbox. the motor will remain without a lower support, and then you need to fix it. You need to do this like this:
- Take a powerful wooden beam, the length of which is about 1.5 m.
- Secure the struts of the front struts so that it is located above the engine.
- Secure the motor to the beam using a chain or the strongest ropes.
After the motor is fixed, you can safely disconnect the rear as well as the left support from the machine frame. Then, move the box in the opposite direction from the motor until the input shaft is released from the clutch. Care should be taken not to break the petals placed on the clutch diaphragm spring.
In principle, the whole procedure is completed, now the checkpoint from the VAZ 2108 engine can be disassembled further to change worn elements.
Gearbox improvements with gear ratios
Many of the techniques used in the tuning of the transmission have been tested in motor sport. For any car, especially a sports one, the gearbox is an important element in the implementation of the dynamic qualities of the engine. Properly selected gear ratios VAZ 2108 make a car with a rather weak power unit fast.
Cars that are serious preparation, use cam gearboxes. They are determined by many advantages - they can withstand quite large loads (using the shape of the tooth and how the gear-cam clutch engages). They need less time to switch gears (due to incomplete clutch release or, without generally squeezing), all the more so, synchronizers (which simply do not) do not destroy.
But nevertheless, cam gearboxes are practically unsuitable for ordinary route advancement, since they produce a lot of noise (due to the use of spur gear pairs), they have a “hard gear shift” and have a fairly small resource. In addition, they are much more expensive than synchronized ones, and must be constantly maintained professionally.
Synchronized gearboxes differ from conventional gearboxes only in gear ratios. Separate situations (VAZ of the eighth model) allow expansion to the sixth gear. Good performance of the gearbox is carried out by the effective selection of the gear ratios of the main gearbox pair, the primary shaft and the driven gears of the secondary shaft. The choice of gear ratios is due to the power, as well as instant capabilities of the motor, wheel diameter, and most importantly from the desires of the motorist.
Under gear ratio Gearbox VAZ 2108 mean the ratio of the number of teeth on the driven gear to the number of teeth on the drive. If it is increased, the transmission will become "more powerful", also "shorter", in another way, the engine will wind the required number of revolutions. Auto speed is also gaining fast, you just need to change gears often. This moment will only be reflected in a certain decrease in the highest speed of the applied transmission.
For example, we take a ride on a VAZ of the eighth model with a 1.3 liter engine. with the main pair 4.5. It feels as if something very powerful was placed in the engine compartment, certainly not VAZ. Although the driver often needs to switch the gear knob of the VAZ 2108, but with any action, even at the traffic lights, the car is the first. In sports cars, gears use the most “extreme” ones - 4.7, and on cross machines - 5.1 at all.
How to replace a gearbox on a VAZ 2108 car
Not in all cases the repair of the VAZ 2108 checkpoint is reasonable, the exchange in most situations is more reasonable and simpler. You can buy a checkpoint new or used. The choice of a node is determined by the advantages, monetary capabilities of a motorist. It’s advantageous to buy a used box at a parse. In sales, there are serviceable spare parts with less than half capacity. The merits of used components are clear.
The checkpoint, without any factory defects (passed the test by the track), was diagnosed by the service center professionals before the sale, it is serviceable and efficient, and for all that its cost is lower compared to the new one. Actually, for a VAZ 2108 checkpoint, the cost is determined by the nodal type (4 or 5 band), the level of wear. By installing this checkpoint, you can save finances, as well as time for repairs.
It is possible to replace the VAZ 2108 gearbox from 4-speed to 5-speed. Then the capabilities of the car will become several times more, it will also depend on the type of engine. After all, it so happens that with a 4-band gearbox the car seems to lack one more speed.
In the event of a gearbox output shaft failure, it should be corrected.
- It is necessary to clamp the secondary shaft of the VAZ 2108 gearbox in a vice with metal soft linings on the lips.
- By means of 2 mountings, it is necessary to compress the ball bearing standing behind the output shaft.
- Remove thrust ring.
- Remove 4th speed driven gear.
- After that, remove the needle bearing of the 4th speed driven gear, and be sure to mark it.
- Then remove the spacer washer from the secondary shaft.
- Using 2 mounts, move the 3rd and 4th speed synchronizer from the splines of the secondary shaft through the third speed gear.
- Remove the 4th speed needle bearing sleeve.
- Then remove the 3rd and 4th speed synchronizer with the 4th speed locking washer. Mark the lock washer of the synchronizer with respect to the synchronizer clutch.
- Then remove the blocker from the secondary shaft. 3rd speed gear synchronizer washer, then mark regarding synchronizer clutch.
- Remove the 3rd speed gear from the secondary shaft.
- Remove the 3rd speed gear needle bearing from the secondary shaft, then mark the needle bearing.
- Remove the thrust washer of the abutment rings.
- Remove 2 thrust halves from the secondary shaft.
- Remove the ball that secures from the bore on the secondary shaft.
- Remove the 2nd speed gear from the secondary shaft.
- Remove the 2nd gear pinion bearing, then mark it.
- Remove the lock washer (spring) from the secondary shaft.
- Place the secondary shaft of the 1st speed gear on the vice lips, then by hitting the end of the secondary shaft with a wooden mallet to compress the 1st and 2nd speed synchronizer from the splines of the secondary shaft.
- Remove the 1st and 2nd speed synchronizer from the output shaft from the lock. 2nd speed synchronizer washer.
- Next, remove the ring that blocks the 1st speed from the secondary shaft, then mark the synchronizer lock washer with respect to the synchronizer clutch.
- Remove first speed gear.
- Remove retaining ring.
- Squeeze the needle bearing lock of the 1st speed slightly and remove it by sliding the latter along the length of the secondary shaft. After marking the needle bearing.
- Turn over the secondary shaft, use 2 large screwdrivers to compress the inner bearing washer in front of the secondary shaft. After removing the thrust washer.
- Clean, rinse and dry the output shaft elements well. Good to inspect them.
- Check the condition of the shafts. If the bearings are worn, they must be replaced. Slots shafts must be without dents and all kinds of defects.
- Check the position of the gearbox of the VAZ 2108 gearbox. In case of chipped teeth, any other damage, the gears must be changed.
- Check in what situation the bearings are and in case of damage replace them.
- The radial clearance of existing ball bearings should not exceed 0.05 millimeters. Check this method with an indicator.
- Next, check the position of the lock. synchronizer rings. If there are nicks and all kinds of chips, you should change them.
- Next, check the gap between the gears and the locking rings. The smallest clearance should be 0.6 millimeters. In case of less clearance, block. the ring should be changed.
- If there are scuffs and cuffs on the thrust washers, as well as the retaining rings, be sure to change them.
- Assemble the secondary shaft in the same way as removed. Lock rings with tags marked earlier. Put the latest rings in such a way that they fit with the grooves of the hub.
- Press the ball bearing at the rear of the secondary shaft by means of the required mandrel, making extra effort to the ring inside the bearing
- Once assembled, you should check the action of synchronizers. By moving their couplings manually to the proper gear position.
- In general, the bearings of the gearbox of a VAZ car are thus removed.
Existing PPC ranks
The ranks of the VAZ 2108 checkpoint: 1 - 3.42, 2 - 2.11, 3 - 1.35, 4 - 0.96, 5 - 0.78, 6 - 0.69
They are also called “commercial”, because for many years they were considered quite famous, as well as sold-out ranks. In general, this is valid at the moment. Elongated first speed, second and fourth - reduced. Any changes are minimized (five percent), and this is enough to correct the flaws of the staffing. In most cases, it is delivered with GP 4.1. The good news is that he is within normal limits. Provides advanced overclocking.
KP front-wheel drive VAZ
The first VAZs of the eighth model, off the assembly line in 1984 of the last century. They were equipped with 2-shaft gearboxes, which were combined in 1 housing with a differential. Since then, the gearboxes have been updated in every way. But since there have been some changes to the elements, they are not entirely interchangeable. In the first VAZs of the eighth model, 4 VAZ 2108 gearboxes were installed, as well as 5-speed gearboxes without a probe.
At the moment, there are almost none left. In 4-band, the main pairs were 4.1, also 3.9. In the five-band 3.9, also 3.7. They decided not to pamper with a large choice in the concern and applied only one main pair - 3.7. As for gear ratios, they were, and still are, only one for all cars.
Gearbox replacement tips
Many drivers for changing to a VAZ 2108 4-speed gearbox on a 5-speed gearbox. Thus, the speed probability of the car increases, the acceleration dynamics is improved. Nevertheless, a 4-band gearbox is already the last century. And for the modernization of your car, just 5 is suitable, and in some cases they even put a 6-speed gearbox, for which the same bearings of the VAZ 2108 gearbox are suitable.
A few words in conclusion on all of the above
The VAZ gearbox of the eighth model implements torque reform, transmitted from the motor in magnitude and direction. This moment is necessary to maintain the desired speed, well, and car cross-country ability, for the greatest economy of the motor and the advancement of the car in reverse. In addition, the gearbox disconnects the motor and transmission for stopping and parking the car, and even during inertia advancement with the existing motor. For all this, you need a gearbox.