UAZ loaf gearshift mechanism. Everything you need to know about the gearbox and transfer case UAZ. Gearbox removal process

Assemble the gearshift mechanism for cars of the UAZ-31512 family in the following order:

1. Install the rubber sealing ring (fig. 114) in the shift shaft stuffing box cover.

   Rice. 114. Installing the sealing ring of the shift shaft cover

2. Install the rubber sealing ring in the hole under the axis of the selector lever 23 (see Fig. 105).

   
   Rice. 105. Gearshift mechanism for cars of the UAZ-3741 family:
   1-rod of the fork of inclusion of a backing; 2-reverse fork; 3-rod of the fork of inclusion of III and IV gears; 4-fork III and IV gears; 5-fork I and II gears; 6-rod of the fork of inclusion of I and II transfers; 7- cotter pin-wire; 8 - plug; 9-washer; 10-shift shaft; 11-side cover; 12-gear shift clutch; 13-blocking spring; 14-gasket; 15-gland cover; 16-shift lever; 17-cork; 18.20 - retainer springs; 19-lock plunger; 21-ball lock; 22 gear selection lever; 23-selective lever; 24-pin; 25-reversing light switch; 26-stub

3. Install the clutch (Fig. 115), thrust washer, spring thrust cup and spring onto the shift shaft. Insert the shaft into the side cover housing and install the gland cover with gasket, secure the cover with three bolts.

   
   Rice. 115. Assembling the gear shift shaft

4. Install the selector lever assembly with the axle (fig. 116) into the cover body so that the lever enters the groove of the shift clutch. Lock the lever with a pin, which you hammer in from below.
5. Turn the side cover over with the machined flange up and insert into the sockets of the spring retainers and the balls of the III and IV gears and the reverse rod using a mandrel (see Fig. 113).

   
   Rice. 113. Device for assembling rods and clamps:
   a-assembly of the latch; b-stem installation

6. Install the reverse fork on the stem from the side opposite the retainer, and, having sunk the retainer ball (Fig. 117) into the cover body using a mandrel (see Fig. 113), set the stem to the neutral position. So sequentially collect all the rods (Fig. 118) and forks. Install lock crackers between the rods.

   
   Rice. 117. Assembling the stem and reverse fork

   
   Rice. 118. Assembling the stem and fork of switching III and IV gears

7. Fasten the forks on the rods with conical bolts and cotter them with wire (Fig. 119), which should not interfere with the movement of the forks. When attaching the forks, the shift clutch lever must be in the groove of the forks.

   
   Rice. 119. Cotter pins for fork bolts:
   1-bolt; 2-pin-wire

8. Insert the detent ball and spring into the hole in the 1st and 2nd gear rod and tighten the plug. At the same time, keep in mind that the spring of the rod retainer of I and II gears in the free state is longer than the other two springs of the rod retainers.
9. Install six plugs in the end holes of the cover body, a plug in the hole for the shift shaft and caulk them.
10. Install the selection and shift levers (Fig. 120) on the splines of the shafts and secure them with nuts and spring washers.

    
    Rice. 120. Installation of external selector and shift levers

The correct position of the levers is checked with the gears in the gearbox in neutral position after the shift mechanism is installed on the gearbox in accordance with Fig. 121.

Rice. 121. The position of the selector lever and the shift lever after installing the mechanism on the gearbox:
A-corresponding to reverse; B-corresponding to the inclusion of III and IV gears; B-corresponding to the inclusion of I and II gears;
1-selection lever; 2-shift lever (in neutral position)

Dismantling the switching mechanism of cars of the UAZ-31512 family (Fig. 8)

Rice. 1. Gearshift mechanism for cars of the UAZ-31512 family

Disassemble in the following order:

Rice. 2. Removing the stem hole plugs

1. Unscrew the four screws of the shift lever support and remove the support with the lever and the preload spring (this operation is done before removing the entire unit from the car).

2. Remove the three stem hole plugs from one side of the bonnet (Figure 2).

Rice. 3. Pressing out the shift fork rods

3. Turn away a stopper of a nest of a clamp of a rod of I and II transfers and take out a spring and a ball.

4. Loosen and unscrew the locking screws of the forks.

5. Press out the rods (Fig. 3) of the shift forks through the holes in the cover where the plugs were removed, and remove the forks.

When pressing out the rods of III and IV gears and reverse, do not lose the retainer ball ejected by the spring.

6. Remove the springs and stem retainer balls.

7. Take out two lock plungers through an aperture of a clamp of I and II transfers.

8. Remove the three screws and remove the fuse cover and return spring.

9. Slide the safety plunger out, remove the circlip and remove the plunger. At the same time, hold the plunger retainer ball from falling out.

10. Remove the spring and detent ball.

Rice. 4. Gear shifting mechanism for cars of the UAZ-3741 family

Dismantling the switching mechanism of cars of the UAZ-3741 family (Fig. 11)

1. Remove the three stem hole plugs in one end of the cover (see Figure 9).

2. Loosen and remove the fork locking screws.

3. Turn away a stopper of a nest of a latch of a rod of I and II transfers and take out a spring and a latch ball.

4. Press the stems (see Fig. 10) through the holes in the cover where the plugs were removed and remove the forks. When pressing out the rods of III and GU gears and reverse, do not lose the retainer ball ejected by the spring.

5. Remove the springs and stem retainer balls; remove the two lock plungers through the hole of the latch of I and II gears.

6. Unscrew the nut and remove the lever 22 from the slots (see Fig. 11),

7. Knock down the pin 24 of the lever axle 23 and remove the axle together with the selection lever.

8. Turn away a nut and remove the lever 16.

9. Turn away three bolts, remove a cover 15 of an epiploon and take out a spring. Having lowered the shaft 10 with the coupling 12 and two washers, remove the shaft through the side cavity of the cover. Before removing the levers 22 and 16, note the mutual position of the levers on the rollers in order to set the levers to their previous position.

Disassembly of the gearshift control mechanism for cars of the UAZ-3741 family

Disassemble in the following order:

Rice. 5. Gear shift control mechanism for cars of the UAZ-3741 family

1. Disconnect the rods 8 and 11 (Fig. 5) from the levers 9 and 10.

2. Unscrew the rods 5 and 14 from the levers 6 and 13.

3. Disconnect an arm 12 intermediate levers.

4. Remove an arm of the mechanism together with the lever of 1 gear change.

5. Wash the parts of the control mechanism.

6. Detect wear in the levers and rods by external inspection.

7. Replace worn parts.

Assembling the gearshift control mechanism for cars of the UAZ-3741 family

Assemble the mechanism in the reverse order of disassembly. After assembly, adjust the gearbox control mechanism.

Adjust by changing the length of the horizontal - 8.11 (see Fig. 5) and vertical - 5, 14 rods in the following order:

1. Before starting the adjustment, set lever 9 to the neutral position (N), and lever 10 to position III–IV until it stops against the blocking spring.

2. Put the shift lever 1 in the position corresponding to the choice of gears I and II. In this position, connect and secure the selection rods 8 and 14 without allowing the levers to be pulled up.

3. After that, put the lever I in the position corresponding to the choice of gears III and IV and also freely connect the shift rods 5 and 11.

4. At the end of the adjustment, check the completeness of the gears. To do this, turn on the first gear and make sure that the rods and levers do not rest against adjacent parts.

Perform the same check by turning on the reverse gear. At the same time, pay attention to the fact that the intermediate lever 6 does not rest against the frame cross member and mudguard.

With the reverse gear turned on, the gap between them should be 2–3 mm.

Assembling the gearshift mechanism for cars of the UAZ-3741 family

Rice. 6. Installing the shift shaft cover O-ring

1. Install the rubber o-ring (fig. 6) in the shift shaft stuffing box cover.

UAZ cars (loaf) have the most spacious body. The body of the machine is made of durable material. The vehicle is equipped with security systems, a durable power unit that is capable of developing more than 100 horsepower, and a transmission system.

The all-wheel drive cargo-passenger UAZ, which has increased cross-country ability, began to be mass-produced at the Ulyanovsk Automobile Plant in the mid-1960s.

On cars of the UAZ-452 family of a new model, there is a manual gearbox (four-speed). Inertial-type synchronizers provide easy gear shifting. The five-speed ADS gearbox is synchronized in all forward gears.

UAZ can be equipped with a 5-speed manual transmission Daimos (DYMOS). This gearbox is known for its reliability. The average resource of its work is 300,000 km. The fill plug is located in the middle of the box, drain from the bottom. They can be unscrewed with a hex wrench. When oil is drained, special containers should be prepared. New fluid must be filled up to the level of the oil filler hole on the box. The dipstick allows you to accurately determine to what mark the liquid is filled. An alternative to the probe can be a long nail. For preventive purposes, every 15,000 km it is necessary to measure the oil level.

The presence of mechanics on this version of the vehicle is fully justified. It is important to use such a machine on rough terrain, off-road. In addition to this, there will be no problems with towing.

The gearbox has external shift levers. The lever in the cab moves freely both parallel and perpendicular to its axis.

The machine is equipped with a transfer case. In the design of the transfer case on the UAZ 452: drive axle shafts, gears. All listed components are in a cast-iron crankcase. The crankcase and cover are connected with nuts. The shift fork rods are securely fixed in the cover.

There is a slot, bearings. There is a helical gear for the speedometer drive. An intermediate shaft is fixed on the "loaf" bearings. This box has reliable gears with straight teeth.

Thus, the checkpoint on the UAZ 452 consists of many components and assemblies. This unit needs regular maintenance.

The need to diagnose the gearbox UAZ model 452

This vehicle must be diagnosed if control began to deteriorate, characteristic creaks began to be heard when gears were changed or gears began to change spontaneously. The UAZ transfer case should be checked if the grip of the wheels with the road has noticeably deteriorated, a rumble begins to appear, an increasing noise during its operation.

During the passage of maintenance, the masters must check the system for oil leaks, the level of lubrication. All worn parts in the transmission system must be replaced with new ones. Also, diagnostics involves lubricating the axis of the levers, adjusting the front links.

Scheduled diagnostics in a professional auto repair shop allows you to accurately determine the existing nature of the problem with the box, eliminate existing problems at an early stage.

Causes of breakdowns

As a rule, the need to replace the main components at the gearbox arises with their natural wear and tear.

Causes of gearbox breakdowns

The main reason for oil leakage from the gearbox is the presence of an increased level of fuel in the system. For a gearbox on a UAZ, high-quality oil should be used. If the liquid does not have the proper quality, then characteristic noises from the side of the box may occur due to this. When the synchronizer or its parts are worn out, it is always difficult to change gears. Pay attention to the details of the switching mechanism. When the gear teeth are deformed, self-disengagement of gears is often noted.

Gearbox removal process

Repair of a checkpoint on a UAZ 452 is quite possible to do it yourself. This requires:

• a set of wrenches, including the wrenches needed to tighten the nuts;
• screwdrivers;
• a hammer;
• chisel;
• pliers.

Dismantling algorithm.

The car must be on level ground. It is necessary to drain the oil from the two boxes by unscrewing the drain plugs. Next, the front seats, hatch halves, clutch release fork, transverse frame, gear levers from the boxes are removed.

The speedometer shaft, suspension mounts in the undercarriage, brake levers are subject to removal. As a result, an exit to the clutch housing opens. A box is fixed on it with fastening nuts, which must be unscrewed, then the UAZ gearbox is carefully extended along with the transfer gearbox until the splined shaft exits the flywheel. The driver will need an assistant to remove the box.

The assembly of the UAZ gearbox requires due attention. With self-assembly, the driver may have difficulty installing the input shaft in the clutch system. With this process, it is necessary to actively move the box so that the shaft gets into the splines.

As soon as the disassembly into individual component parts has taken place, the box must be washed in kerosene and dried. All component parts are checked for integrity. First of all, this concerns the crankcase, shafts. If the threads on the shafts are damaged, they must be replaced. It seems dangerous to operate the machine if the gears are chipped.

Thus, the timely repair of the UAZ "loaf" checkpoint helps to extend the life of the box.

The gearshift mechanism of a four-speed semi-synchronized UAZ-452 family car is mounted in the side cover of the gearbox. The shift forks are attached to the rods with a conical screw cottered with wire.

The movement of the forks when shifting gears occurs together with the rods, which have a socket for a locking screw and grooves for clamps and a locking device. The middle rod has, in addition, an intermediate pin of the locking device. When one of the gears is turned on, the rod moves and locks the adjacent rods with a rod through the crackers.

Thus, each of the remaining rods is closed with a key block and cannot be removed from the neutral position until the previously switched rod is returned to the neutral position. The same lock prevents the simultaneous inclusion of two gears.

The forks in the neutral position and in the positions with the gears engaged are fixed with balls. To switch the forks, a clutch with a lever is used, planted on the slots of the vertical shaft. The head of the clutch lever fits into the grooves of the forks. The clutch can move along the roller in the axial direction. When the roller rotates, the clutch turns and its lever moves one or another fork.

In this case, in the uppermost position, the clutch is connected to the fork of the first and second gears, in the middle position - to the fork of the third and fourth gears, the extreme lower position - to the reverse fork. The middle position of the clutch is fixed by the clutch stop against the washer against which the spring rests. In order for the clutch to take its lowest position, additional force must be applied to compress the spring. At the outer end of the roller, splines and threads are cut for installing the gear lever.

To move the clutch up and down, a control lever is used, which rotates on a roller and enters the groove of the clutch. The outer end of the roller has slots and threads for attaching the outer lever. The rollers are sealed with rubber O-rings.

The external control and shift levers have a splined hole at one end, and holes at the other end into which rubber pads with brass bushings are inserted. When installing on the slots of the control and switching levers, a deviation from the positions within 5 degrees in any direction is allowed.

Positions of external gear levers.

This mechanism consists of two levers - control and switch, rotating in mutually perpendicular planes. Both levers are mounted in a bracket that is attached to the cab. At the end of the long arm of the control lever there is a hole for connecting the rod, at the end of the short arm there is a fork into which the lever enters. In the middle position, the lever is fixed with a locking ball.

The shift lever at one end is connected to the rod, the other - to the main gear lever using a fork protrusion with holes. The main lever is mounted on an axle screwed into the shift lever body. The axle is locked with a locknut. The hinge of the main shift lever is protected from dust by a polyethylene seal that closes the hole in the cab air duct. The edges of the hole are sealed with foam rubber, pressed by a steel clip.

The main lever is first rotated transversely relative to the shift lever and then only rotated with the shift lever into the desired gear. A vertical link is attached to the control lever with a pin, cotter pin, flat and spring washers. The shift lever is connected to the vertical link with a pin and cotter pin.

The lower ends of both rods are threaded, allowing you to change their length. To adjust the length of the rods, fingers locked with two nuts are put on their threaded ends. By unscrewing or tightening the nuts, it is possible to change the length of the rods without disassembling the connections.

The cylindrical parts of the pins with square heads are connected to the intermediate levers with cotter pins, flat and spring washers. The intermediate lever assembly is mounted on the second cross member of the vehicle. All intermediate levers are mounted on one axis: the upper intermediate control lever is knurled, the lower intermediate control lever is fixed with a radial pin, the intermediate shift lever is loose on a bronze bushing. Lubrication holes are made in the axle.

The intermediate levers with the levers are connected by horizontal rods, the opposite ends of which are connected to the gearbox levers with the help of fingers with square heads.

The operation of the control mechanisms and gear shifting of the UAZ-452 gearbox.

The lever in the cab can move in two planes - parallel to the vehicle axis and perpendicular to it. When this lever moves perpendicular to the axis of the car, its lower end moves the control lever and through the system of rods and intermediate levers enters the shift clutch into the desired position.

When moving the horizontal thrust backwards, the shift clutch is connected to the fork of the first and second gears, when moving forward - to the reverse fork.

When the lever is moved in the cab in a direction parallel to the axis of the car, the gear selected by the previous movement is switched. The control lever of the control mechanism remains stationary, and only the shift lever rotates.

Adjustment of the control mechanisms and gear shifting of the UAZ-452 gearbox.

The control mechanism and the gearshift mechanism, after adjustment, must ensure the correct operation of the gearbox and the comfort of the driver. The adjustment procedure is as follows:

- Set the levers on the gearbox cover to the neutral position.
- By changing the length of the horizontal rods, install the intermediate levers so that their lower arms are directed vertically downwards.
- By changing the length of the vertical control rod, install the mechanism control lever on the latch.
- Then select the length of the vertical shift rod so that the lever handle in the cab is in the middle position between the shield and the hood.
- Securely fasten the nuts of the rods.

By successively engaging the first gear and reverse gear, it is necessary to check the correct adjustment of the drive. In these positions, the rods and intermediate levers must not rest against adjacent parts. The lever in the cab should not be too close to the instrument panel or hood so as not to injure the driver's hands. The inclusion of gears in the gearbox must be complete, that is, the engagement rod must be on the latch.