Gearbox VAZ 2109 5 mortar - device, diagram

RANGE Gearbox 05 (KPP 2108) (I - 2.92; II - 1.81; III - 1.27; IV - 0.96; V - 0.78; VI - 0.69)

Requires 1 washer 2 mm for 4th gear

Belongs to the category of sports rows. 4 gears changed. 1st, 2nd and 3rd gears are lengthened (as in 6th), 4th gear is shortened (as in 8th by 5%), 5th is standard. Usually GP 4.1 is installed. On forced engines - with GP 3.7, 3.9.

RANGE Gearbox 06 (KPP 2108) (I - 2.92; II - 1.81; III - 1.27; IV - 1.06; V - 0.94; VI - 0.78)

Requires 1 washer 2 mm for 4th gear

Sports row. Classic installation - with 6th gear and 4.1 (4.3) gearbox. 1st, 2nd and 3rd gears are lengthened (1st significantly), 4th and 5th are shortened. 5th gear of the 6th row is 4th from the standard row.

RANGE Gearbox 07 (KPP 2108) (I — 2.92; II — 2.05; III — 1.56; IV — 1.31; V — 1.13; VI — 0.94)

Requires 1 washer 2 mm for 4th gear and 1 for 5th gear

Very short - sports (rally, motocross) series. Without 6th gear, it is impossible to achieve a high maximum speed. With 3.7 GP in 5th gear at 5000 rpm. – 128 km/h. When installed with GP 4.1, 4.23 can be used, for example, for short distance competitions such as drag racing.

RANGE Gearbox 08 (KPP 2108) (I — 3.42; II — 2.11; III — 1.35; IV — 0.96; V — 0.78; VI — 0.69)

It is also called “commercial”, since for many years it was the most popular and best-selling product. However, it remains relevant today. 1st gear extended, 2nd and 4th shortened. All changes are minimal (5%), but this is quite enough to correct the shortcomings of the standard series. Most often installed with GPU 4.1. Inexpensive, which is nice. Provides improved acceleration dynamics.

Technical characteristics of the VAZ 2108 gearbox

Dismantling the box

Sequential gearbox for VAZ 2108. Gearbox
If you can hear an incomprehensible noise in the gearbox, the car becomes difficult to change gears or does not want to move at all, you may need to remove this mechanism. Do-it-yourself repair of a VAZ 2109 vehicle can be done in any garage, having all the necessary tools at hand. The VAZ 2109 has a rather complicated gearbox removal, so you should prepare for this procedure in advance.

The box is located deep enough, so it is almost impossible to remove it alone. In this case, you may need special crowbars, the help of other people and some tools in order to properly disconnect it. In general, you can seek help from a service center, where the service will be carried out using special equipment. But, you can repair it yourself by removing it carefully without damaging other important parts.

Malfunctions and their elimination

Gearbox repair largely depends on the nature and type of fault. There are several options for the breakdown of this unit, in each of which appropriate actions should be taken to eliminate them.

In most cases, problems with the gearbox are eliminated by dismantling and disassembling it. Do not take on this type of work without the proper skills and experience.

What to pay attention to

So, following the instructions, we disassemble the gearbox of your VAZ 2109. Along the way, pay attention to the following points:

1. Bearings. When they wear out, a noise from the box occurs. Plus, worn bearings negatively affect the condition of other gearbox elements;
2. Synchronizers and sealing washers. If their condition leaves much to be desired, then the gears shifted poorly precisely because of them. Replace them;
3. Clutch system, cotters, coupling hub clamps. All this must be replaced separately if there are signs of wear or defects;
4. Blocking rings, synchronizers. If there are chips or nicks, don’t even think about alternative solutions, replace them immediately;
5. Bearing tracks. Over time they wear out. If signs of wear are found, perform a complete replacement. In this state, they were only a short time away from breaking;
6. Gap between gears and locking rings. Normally it is no less than 0.6 mm. In case of deviations, there is only one solution - replacing the rings;
7. Retaining rings. If elasticity is lost, these elements must be changed, since they will no longer be able to perform their functions.

When assembling the gearbox, do not forget to lubricate the new gaskets with a layer of lithol. And when pressing the oil seals, do it with the working edge inward. The metal clip should be located on the outside.

During the process of reassembling the gearbox, all rubbing components should be treated with oil, and do not forget about the sealant for connecting the clutch housings and gearbox. Doing everything yourself is quite possible.

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The VAZ-2109 gearbox is a highly complex element, without which the vehicle will not be able to move. The first production of the gearbox began in 1987. It was then that the first five-door hatchback appeared, which is still very popular today.

What to choose

The design of the VAZ 2109 gearbox is imperfect, but this is not a good reason to change it completely. The design itself is reliable, it just requires some modifications. The best option is to replace the problematic part, which causes frequent unit breakdowns, or install new components.

1. If you need to change the gear ratios of your original transmission, replacing a pair of gears from 17-tooth to 15-tooth parts will do. This modernization increases the efficiency of acceleration, the transition time from gear to gear is reduced, but the maximum speed of the car decreases. Perfect for traveling in urban areas.
2. Installing sports gears makes the gears “longer”, that is, switching from one gear to another is required less often, while the dynamics of acceleration and maximum speed are practically not lost. This gearbox tuning is suitable for those who want to increase the speed characteristics of their nine. Mainly used after replacing the engine with a more powerful analogue.
3. You can try replacing the original secondary shaft of the nine. The problem with this part is that it is hollow inside. Due to dynamic loads on the assembly, it often happened that this particular shaft shattered into pieces, which led to the final breakdown of the entire gearbox due to fragments stuck in the teeth. Replacement is made with a solid analog shaft for a pair of gears with a gear ratio of 4.13.
4. Want to make your car more agile on the track? Buy additional sports hub bearings for tuning. They will slightly improve the performance of the chassis, but the main thing is that they are more reliable than factory parts.
5. Start adjusting the differential, but do it only in reputable auto repair shops and service stations. Incorrect adjustment of the part will lead to frequent breakdowns or loss of vehicle controllability.

There are a lot of tips and fairly detailed instructions on how to independently replace a part of an assembly or the entire assembly, but you don’t need to do this if you don’t know the architecture of the car. When carrying out many works, practice and clear knowledge of the matter are required, so it is better to entrust the work to the masters at the service station.

If you need to improve the gear shift mechanism of a VAZ 2109, then before modifying it you need to purchase some additional parts and replace the factory ones with them. This option for solving problems is the cheapest and simplest. Installing an automatic transmission on a VAZ 2109 is not always justified. This modification will simplify driving the car, slightly increase the working life of the unit and allow it to smoothly transition from one speed mode to another. On the other hand, not every owner of a nine can handle repairs, maintenance and installation of automation, so taking into account the costs, this solution is not effective.

About the oil

For good performance of the VAZ 2109, all important components must be coated with oil. Typically, the manufacturer independently determines the brand of engine and transmission parts that are recommended for use in cars of a given model.

If you do not have such information, you should consider the main purpose of the machine:

• if the VAZ is driven on excellent roads in the regional center, there is a certain type of oil for this;
• if you drive a car, a transmission would be the ideal option.

Remember to maintain the optimal oil level

When filling oil, it should be taken into account that the VAZ 2109 box requires a slightly larger amount. Only this approach will help protect and cover all spare parts located at the crankcase outlet.

Since the gearbox is the second most important element of a car, in the event of the slightest breakdown it is necessary to immediately eliminate the shortcomings. Let's look at the main malfunctions that can occur with the gearbox

Let's look at the main malfunctions that can occur with the gearbox.

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Automatic transmission shutdown

• worn gears and locks on the coupling;
• failure to comply with vehicle operating rules;
• incorrectly selected speed mode;
• incorrect shifting with a poorly adjusted clutch;
• unprofessional gearbox repair (ignoring clutch replacement);
• ignoring repairs in the presence of extraneous noise in the form of crunching.

If you contact a service station in a timely manner, the VAZ gearbox can somehow be saved. If the condition is too neglected, count on expensive repairs.

What do the noises in the 2109 box mean?

There are no silent boxes. Each of them has a maximum permissible noise level, which is established by GOST.

• Extraneous noise from the VAZ box may occur as a result of the operation of gears and bearings;
• Used or low-quality oil also causes noise;
• Sometimes the reason for its appearance may be the operation of the power unit. In this case, the speed may be unstable or a powerful camshaft may be installed.

It takes forever to describe extraneous noises, since each driver hears them differently. To more fully understand the cause, it is necessary to diagnose the transmission.

Crunching sound when changing gear

Excessive or improper use of the vehicle.

If there is a crunching noise, the synchronizer will need to be replaced. If you decide to save money on it, you should expect to buy a whole block of gears in the future.

In addition, the presence of a crunching sound may indicate that it is time to change the used oil. Or perhaps it was filled with the wrong degree of viscosity?

Knocks

If you hear knocking noises in 21099, you should immediately check the gears

Perhaps one of the pairs has a chip; If a knocking noise occurs while driving, or when you switch the gearbox from one gear to another, pay attention to the satellites. Most likely they are the ones that have worn out.

The gearbox on a VAZ burst

Whether or not to purchase a new box is up to you. Judge for yourself, repairing it can cost you the same price as buying a new one.

The box is unstable and switches hard

The cause of this type of problem with box 21099 is the synchronizer or gear. In some cases, this situation may occur when purchasing new gearboxes or after repairing them.

Gearbox synchronizer

In any case, you should know that when buying a new car you need to run it in. Rough operation of the vehicle leads to serious problems.