Repair of VAZ 2109 and 21099 gearboxes. When there is nothing to do

Causes of malfunction and failure

During the operation of the car, the gearbox periodically fails. This is due to the fact that any machine node has its own resource. An important fact is spare parts, which also affect the service life. According to the manufacturer, repairs to the VAZ-2109 gearbox should be carried out once every 50,000 km.

Let's consider the main reasons for the failure of the gearbox of the Zhiguli-2109 car:

• The components of the unit heat up during short-term operation. The first thing that indicates the gearbox is heating up is the gear knob. It transmits thermal energy, which can be felt by the touch of the hand. The gearbox itself gets very hot. A sign may also be a breakdown of one of the gaskets that could not withstand significant heat.
• Noise when the engine is running. When synchronizers fail or gears wear out, they begin to hum, which can be heard even in the car cabin. In most cases, the noise is produced by the bearings, as well as the release mechanism.
• Poor gear shift. The first position does not turn on the first time, or it takes quite a lot of effort to get the lever to hit the desired point.
• When driving, the gears switch off spontaneously. This indicates that the primary and secondary shaft gears are worn out and require replacement.

All these reasons can cause the gearbox to begin to fail and require repair.

What exactly is making noise and why?

Let's try to understand this issue. The main causes of noise coming from the gearbox are:

• improper operation of the gearbox, in particular the use of counterfeit transmission fluid purchased on the black market and operation of a vehicle with a non-working clutch;
• poor quality of gearbox components;
• maximum service life of manual transmission;
• unskilled technical work on diagnostics and repair of gearboxes.

New manual gearbox from VAZ 2109

Repair of gearbox VAZ 2109,2110,2112,2114,2170,1118.

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Repair of VAZ gearbox (1 part). Do it yourself!

Complete box repair

speeds of a front-wheel drive
VAZ
, at home.
I make it from a VAZ 2109
. Principle…

In addition, the main malfunctions that can result in noise in the gearbox are:

• sudden difficulty switching on speed: in order to engage one or another gear, the driver will sometimes need to move the gearbox lever several times to the neutral position with the clutch depressed;
• The box automatically switches off the car’s gear while driving;
• Transmission fluid may leak from the gearbox.

It should also be noted that the VAZ 2109 gearbox can make noise in various conditions: at neutral speed, while shifting gears, or simply while driving at a certain speed. And each of these noises can indicate a different malfunction of the box.

In addition, during diagnostics, one must not forget that only one external sign may indicate several malfunctions in the gearbox. Therefore, it is virtually impossible to visually (i.e., by the type of hum) calculate which component of the box has failed. The damage can only be determined by removing and disassembling the box.

It is also necessary to add that repairing a transmission and eliminating defects requires a lot of knowledge, so it is better not to do this at home. The gearbox is an important unit in the structure of any vehicle, so it is better to entrust its repair and diagnostics to a qualified specialist.

Tuned VAZ 2109

Often the hum of the unit manifests itself:

• when you press the clutch;
• when turning on the third and fourth speeds;
• at neutral speed;
• when driving a car at high speeds.

Most domestic VAZ 2109 car owners face such problems. But if when you press the clutch, extraneous sounds disappear, then this may indicate several breakdowns. In particular, the fifth speed or reverse gear may fail. In addition, the input shaft bearing or release bearing may be faulty.

As practice shows, in the case of bearings the problem is not critical. If noise appeared in your car and then disappeared after several hundred or thousand kilometers, then most likely the remaining bearings were simply ground up by the unit system.

If your VAZ 2109 starts making noise, this does not mean that the bearings or reverse gear have failed. These problems are the most common, but only high-quality diagnostics can specifically determine what has gone wrong.

Contact Yudu's specialists if you need to urgently repair your car's gearbox. Experienced technicians are registered on the website youdo.com who will overhaul your car's control module and provide other maintenance services inexpensively.

With the help of the Yudu service you will find qualified car service center specialists. Private repairmen registered on youdo.com can also offer you professional gearbox repairs.

The contractors carry out work on repairing automatic transmissions of cars, visiting your home at any specified address. Yudu specialists always have the necessary equipment and tools for car maintenance. Professionals with experience registered on the Yudu website are ready to come at any time convenient for you.

Pricing policy for gearboxes and parts in different countries

The cost of components and parts varies in different CIS countries. Even on the territory of the Russian Federation closer to large cities (Moscow and St. Petersburg), the price will be higher than in other regions. Let's consider the main price indicators for spare parts for the VAZ-2109 gearbox in the Russian Federation and Ukraine.

Of course, the price of components depends on the manufacturer, but the table indicated the cost of parts produced by AvtoVAZ.

Self-replacement of the front wheel bearing in a VAZ 21099

According to the vehicle maintenance card, it is necessary to replace the front wheel bearings of the VAZ-2108. Their dimensions are larger than those of similar ones installed on the VAZ 2101-2107 model. Moreover, there are features of the replacement. The “classic” uses tapered bearings; it is imperative to observe the permissible force when tightening the hub nut. Otherwise, the bearing will fall apart and you will have to buy a new one. Eights use cylindrical bearings; when tightening the hub nut, you need to apply as much force as you can - just don’t break the thread.

Cost of overhaul and repair

The cost of repairing a VAZ-2109 gearbox on average in the Russian Federation is 12,500 rubles. It is worth noting that in regions close to Moscow, it will be about 15 thousand rubles. In remote areas - about 11-12 thousand rubles. Thus, it becomes clear that the repair of the VAZ-2109 gearbox (price, in particular) will depend on the region where the restoration work is being carried out.

In Ukraine, the average market cost of reassembling the box, including its removal and installation, will be about 3,500 hryvnia, which, translated at the exchange rate, is significantly less than in the Russian Federation.

Cost of express gearbox replacement

Warranty 1 year or 60,000 km. mileage for work and VAZ gearboxes

New gearbox VAZ 2109

Prices for additional work when repairing a VAZ manual gearbox:

Comprehensive troubleshooting / disassembly /

Replacing the clutch /as a separate job/

Removing and installing a manual gearbox as a separate job - without repair

Replacing the clutch with the gearbox removed

Gearbox diagram VAZ 2108 - VAZ 21099 - VAZ 2115:

gearbox shafts

gearbox gears

gearbox differential

gear selection

Most of the complaints from car owners of the VAZ 2115 family are characteristic noises from bearings. An example of such work on replacing bearings on shafts and gearbox seals in photographs:

Most of the complaints about the operation of the VAZ 2114 family gearbox are not only noise, as a rule it is a crunching noise when engaging 2nd gear. An example of such work in photographs is the replacement of bearings, oil seals, synchronizers, 2nd gear gears, 1st - 2nd gear clutches):

Gearbox repair VAZ 2108 - 2109 - 21099 - 2113 - 2114 - 2115

• The gear shifts with a crunch.
• The appearance of extraneous noise in neutral gear.
• There is play in the VAZ 2109 gearbox. A loose lever indicates the destruction of the hinge or wear of the link.
• Low lubrication level due to transmission fluid leak.

If you need urgent repair of a VAZ 2109 manual transmission, our service center guarantees fast professional assistance. After disassembly, diagnostics and troubleshooting, a specialist will repair the VAZ 2109 gearbox in a short time or completely replace the worn-out unit.

VAZ 2113 gearbox: technical features The next generation of front-wheel drive VAZs is equipped with a 5-speed gearbox: the VAZ 2113 has an updated main pair with a gear ratio of 3.7. The complex structure of the box does not allow unprofessional intervention: repair of the VAZ 2113 gearbox should only be carried out by specialists and only in a car service center. The modified design has a number of typical faults, which are especially common on older cars. Repair of the VAZ 2113 gearbox is required when extraneous noise appears as a result of wear of gears and bearings, problems with oil leakage, and failures when shifting gears while driving also occur. To accurately diagnose the malfunction and replace parts, you must contact a specialized service center: we offer repairs to the VAZ 2113 manual transmission on favorable terms. If you need to buy a VAZ 2113 gearbox, here you can choose and purchase refurbished units; they will cost very little. A used transmission can last for years if handled properly. Replacement will be a profitable solution if the unit is severely worn out and a large number of parts are required to restore it.

Tools and equipment

In order to repair a VAZ-2109 gearbox, certain skills will be required. To perform operations you will also need the following tools:

• Set of heads and keys from 8 to 24.
• Flathead and Phillips screwdriver.
• Small hammer and chisel.
• Small magnet.
• Sealant.
• Oil seal remover.

If unusual situations arise, you may need an additional tool, which you can borrow from your neighbor in the garage.

Disassembling the gearbox

Repairing a gearbox on a VAZ-2109 with your own hands begins with removing the gearbox. It is worth remembering that this unit on the “nine” is removed at the bottom, so you will need a pit or a lift. Let's consider the sequence of actions for removing the gearbox from a car:

• We remove the “minus terminal”.
• The ground wire is disconnected from the crankcase.
• Turn off the speedometer.
• The clutch fork must be disengaged.
• “Hooks”, so-called “brackets”, are mounted on the motor, which are hooked onto a winch or hoist.
• The engine and gearbox are raised.
• The next step is to disable reverse gear and drain the oil from the box.
• Now you can disconnect the rod from the gear selector rod.
• Having unscrewed the fastening bolts, we separate the engine and gearbox.
• Next, the drive shafts are disconnected on both sides.
• Disconnect and dismantle the starter.
• We remove the shaft from the clutch and remove the gearbox from the car.

Now you can carry out basic repairs of the VAZ-2109 gearbox. As well as major restoration work.

If we repair the gearbox on a VAZ-2109 with our own hands, then before doing this the gearbox must be disassembled. Let's look at how to do this:

• We clean the entire surface of the box from dirt. This can be done using a soft brush, as well as a rag soaked in kerosene.
• We unscrew the bolts securing the rear cover and dismantle it.
• We turn on III or IV gear. We fix the shafts and unscrew the 5th gear fork.
• Unscrew the nut on the primary and secondary shaft.
• Using a screwdriver, remove the synchronizer and then the clutch.
• We remove the 5th gear gear from the secondary shaft.
• We also remove the 5th gear drive gear from the input shaft.
• Now we dismantle the bearings. To do this, first remove the retaining rings.
• After unscrewing the clamps, use a magnet to remove the balls.
• We dismantle the gearbox housing.
• After unscrewing the fastening, remove the 1st-2nd gear shift fork.
• We disengage the 5th gear rod and turn it. Now you can dismantle it.
• Remove the fork and reverse gear.
• Now you can pull out both shafts. It is worth paying attention that this is done at the same time so as not to damage other elements.
• We dismantle the gear shift mechanism.
• Press out the front and rear oil seals.
• Disconnect the speedometer drive.
• We disassemble the shafts. Sequentially remove the gears, synchronizers and retaining rings.
• When the gearbox is disassembled, it should be inspected for defects.

Troubleshooting

Before you begin repairing the VAZ-2109 gearbox, you need to identify the main faults:

1. We inspect all parts of the body. If there are cracks or chips, the damaged part must be replaced.
2. After dismantling the bearings, it is necessary to inspect the seats for wear and tear. We do the same with the places where the seals are installed.
3. Synchronizers, gears and forks are examined for wear.
4. We carefully study the shafts. If they have scratches, the part needs to be replaced.

How to do self-diagnosis

At a service station, car diagnostics are carried out using professional equipment; this procedure costs a lot of money. Therefore, drivers simply need to learn how to conduct an independent inspection; it will allow you to understand what is causing the problems with the VAZ-2109 and will save you money.

How does a gearbox malfunction manifest itself:

1. When stopping, periodically look under the car for oil leaks. If there is a leak, it may be necessary to replace the oil seal located in the gearbox.
2. Monitor the change in oil level in the VAZ-2109 engine. Experts say that checking the oil volume should be carried out at least annually, and possibly more often, especially if the machine is actively used. Focus on checking the oil every 20,000 km.
3. When changing gears, pay attention to the smooth movement of the shift lever. If jerking and jamming occurs, then it’s time to think about repairing the gearbox in the VAZ-2109.

Gearbox assembly and repair

The assembly of the VAZ-2109 gearbox is carried out in the reverse order of disassembly. After the gearbox is assembled, it is necessary to fill it with oil. For break-in, you can add traditional fluid marked TAD-17. When the car has driven 500-700 km, it is necessary to drain the break-in oil and fill it with permanent oil. Its quality will determine how long the gearbox will work after basic or major repairs.

It is worth remembering that when reassembling it is necessary to use new gaskets and sealant. Many car enthusiasts recommend not changing the gasket repair kit if they were successfully removed. Professionals advise changing it in any case to eliminate the possibility of gasket breakdown.

To fill the oil in the VAZ-2109 gearbox, the markings 75W-40, 80W-90 are used. The capacity of the box after repair is exactly 3 liters. It is recommended to fill with GL-4 or GL-4/5.

Basic rules for assembling a gearbox on a VAZ-2109

When the parts that were completely worn out have been replaced with new ones, all that remains is to assemble the gearbox. But before that, thoroughly rinse all parts and remember the following requirements:

1. Before laying the gaskets, apply an even layer of lithol to them. The substance ensures that the gaskets move during assembly.
2. When starting to press in the oil seals, focus on the working edge from the inside; at this time, the metal holder should be placed on the outside.