Design, repair and maintenance of the gearbox VAZ 2106
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Design, repair and maintenance of the gearbox VAZ 2106

The gearbox (gearbox) is the main element of the car's transmission. In the event of a critical malfunction, the car will not be able to continue moving, and if it can, then in emergency mode. In order not to become a hostage to such a situation, it is important to know the main points regarding its design, operation and repair rules.

Checkpoint VAZ 2106: general information

The gearbox in the car is designed to change the value of the torque transmitted to the wheels of the car from the crankshaft of the power unit (in our case, through the cardan shaft). This is necessary to ensure optimal load on the power unit when the machine is moving in various modes. VAZ 2106 cars, depending on the modification and year of manufacture, were equipped with four- and five-speed manual gearboxes. Switching speeds in such devices is carried out by the driver in manual mode using a specially provided lever.

Устройство

The first "sixes" rolled off the assembly line with four-speed gearboxes. They had four forward speeds and one reverse. Since 1987, the VAZ 2106 began to be equipped with five-speed gearboxes, with an added fifth forward speed. It made it possible to almost completely "unload" the car's engine during long-distance high-speed trips. The five-speed gearbox was designed on the basis of the four-speed one. Both of these boxes are interchangeable, and their designs are largely similar.

The four-speed gearbox "six" consists of:

  • crankcase with covers;
  • primary, intermediate and secondary shafts;
  • step changers.
    Design, repair and maintenance of the gearbox VAZ 2106
    Five-speed gearboxes VAZ 2106 have almost the same design as four-speed

The gearbox input shaft is mounted on two bearings. One of them (front) is mounted in a socket on the end of the crankshaft. The rear bearing is located in the wall of the gearbox housing. Both bearings are ball bearings.

The rotation of the secondary shaft is provided by three bearings. The front has a needle design. It is pressed into the bore on the first shaft. The middle and rear bearings are installed in a special housing in the crankcase and the bore of the rear cover, respectively. They are ball-shaped.

Gears of the first three stages are placed on the secondary shaft. All of them are engaged with gears on the intermediate shaft. The front part of the shaft is equipped with special splines that serve to fasten the synchronizer clutch of the third and fourth speeds. Reverse gears and speedometer drive are also installed here. The intermediate shaft is also mounted on two bearings: front (ball) and rear (roller).

Stage synchronizers have the same type of design, consisting of a hub, clutch, springs and locking rings. Gear shifting is carried out by means of a mechanical drive, which consists of rods with forks engaged with movable (sliding) couplings.

The shift lever has a two-piece design. Its upper and lower parts are connected by means of a collapsible damping device. This is necessary in order to simplify the dismantling of the box.

The device of a five-speed gearbox is similar, with the exception of some changes in the rear cover and the design of the intermediate shaft.

Read the review of the VAZ-2106 model: https://bumper.guru/klassicheskie-modeli-vaz/poleznoe/gabarityi-vaz-2106.html

The main technical characteristics of the gearbox VAZ 2106

The main parameter that determines the operation of the gearbox is the gear ratio. This number is considered to be the ratio of the number of teeth on the driven gear to the number of teeth on the drive gear. The table below shows the gear ratios of gearboxes of various modifications of the VAZ 2106.

Table: gearbox ratios VAZ 2106

WHA 2106WHA 21061WHA 21063WHA 21065
Number of steps4445
Gear ratio for each stage
13,73,73,673,67
22,12,12,12,1
31,361,361,361,36
41,01,01,01,0
5NoNoNo0,82
Reverse gear3,533,533,533,53

What checkpoint to put

Some owners of "sixes" with four-speed gearboxes are trying to improve their cars by installing five-speed boxes on them. This solution allows you to make long trips without much stress on the engine and with significant fuel savings. As can be seen from the table above, the gear ratio of the fifth gear of the standard gearbox VAZ 21065 is only 0,82. This means that the engine practically does not “stress” when driving at fifth gear. In addition, if you move no more than 110 km / h, then a serviceable power unit in such a situation will consume no more than 6-7 liters of fuel.

Gearbox from another VAZ model

Today on sale you can find new gearboxes from VAZ 2107 (catalog number 2107-1700010) and VAZ 21074 (catalog number 21074-1700005). They have characteristics similar to those of the VAZ 21065. Such gearboxes can be installed on any "six" without any problems.

Checkpoint from a foreign car

Among all foreign cars, there is only one, with which the gearbox can be installed without alterations on the VAZ 2106. This is the “big brother” of the classic VAZ - the Fiat Polonaise, which even outwardly resembles our “six”. This car was produced not in Italy, but in Poland.

Design, repair and maintenance of the gearbox VAZ 2106
"Polonaise" even outwardly similar to our "six"

Also on the VAZ 2106, a box from Polonez-Karo is suitable. This is a speedy version of the regular Polonaise. Below in the table you will find the gear ratios of the gearboxes of these cars.

Table: gear ratios of the gearbox of Fiat Polonaise and Polonaise-Caro cars

"Polonaise"Polonaise-Caro
Number of steps55
Gearbox ratio for:
1 gears3,773,82
2 gears1,941,97
3 gears1,301,32
4 gears1,01,0
5 gears0,790,80

The only thing that will need to be redone when installing a gearbox from these machines is to expand the hole for the gear lever. In Fiats, it is larger in diameter and has a square rather than a round section.

Design, repair and maintenance of the gearbox VAZ 2106
The checkpoint from the "Polonaise" is installed on the VAZ 2106 with little or no modifications

The main malfunctions of the VAZ 2106 gearbox

Being a mechanical device, all the more subject to constant stress, the gearbox cannot but break down. And even if it will be serviced in accordance with the requirements of the car manufacturer, there will still come a time when it will be “capricious”.

The main faults of the VAZ 2106 gearbox include:

  • oil leakage;
  • noise (crunch, crackle, squeal) when the speed is turned on;
  • uncharacteristic sound for the gearbox operation, changing when the clutch is squeezed;
  • complicated (tight) gear shifting;
  • lack of fixation of the gearshift lever;
  • spontaneous shutdown (knocking out) of gears.

Let's consider these malfunctions in the context of the reasons for their occurrence.

Oil leaks

Leakage of grease in the gearbox can be identified by marks on the ground or engine crankcase protection. It is impossible to delay the elimination of this problem, because an insufficient oil level will necessarily lead to a number of other malfunctions. Reasons for leakage can be:

  • damage to the cuffs of the shafts;
  • wear of the shafts themselves;
  • high pressure in the gearbox due to clogged breather;
  • loosening of the bolts of the crankcase covers;
  • violation of the integrity of the seals;
  • loosening the oil drain plug.

Noise when turning on gears

Extraneous noise that occurs when shifting gears may indicate such malfunctions:

  • incomplete clutch disengagement (crunching);
  • insufficient amount of oil in the box (hum, squeal);
  • wear of gears or parts of synchronizers (crunching);
  • deformation of the lock rings (crunching);
  • bearing wear (hum).

Sound uncharacteristic for the operation of the checkpoint

The appearance of a sound that is uncharacteristic for the normal operation of the gearbox and disappears when the clutch is depressed may be due to:

  • low level of lubrication in the box;
  • gear damage;
  • bearing failure.

Difficult gear shifting

Shifting problems that are not accompanied by extraneous noise may indicate malfunctions such as:

  • deformation or damage to the shift forks;
  • difficult travel of the fork rods;
  • complicated movement of the movable clutch of the corresponding gear;
  • sticking in the swivel joint of the shift lever.

The lack of fixation of the lever

If the gearshift lever occupies the previous position after switching on the speed, the return spring is most likely to blame. It can either stretch or break. It is also possible for one of its ends to slip from the place of attachment.

Switching off (knocking out) speeds

In case of uncontrolled gear shifting, the following malfunctions may occur:

  • damaged synchronizer spring;
  • the synchronizer ring is worn out;
  • blocking rings are deformed;
  • rod sockets are damaged.

Table: malfunctions of the VAZ 2106 gearbox and methods for their elimination

Noise in the gearbox
Bearing noiseReplace defective bearings
Wear of gear teeth and synchronizersReplace worn parts
Insufficient oil level in the gearboxAdd oil. If necessary, eliminate the causes of oil leakage
Axial movement of shaftsReplace the bearing fixing parts or the bearings themselves
Difficulty shifting gears
Sticking of the spherical joint of the gear leverClean the mating surfaces of the spherical joint
Deformation of the gear leverRepair the deformation or replace the lever with a new one
Stiff movement of the fork stems (burrs, contamination of the stem seats, jamming of the locking crackers)Repair or replace worn parts
Stiff movement of the sliding sleeve on the hub when the splines are dirtyClean up the details
Deformation of shift forksStraighten forks, replace if necessary
Spontaneous disengagement or fuzzy engagement of gears
Wear of balls and rod sockets, loss of elasticity of retainer springsReplace damaged parts with new ones
Wear of the blocking rings of the synchronizerReplace locking rings
Broken synchronizer springReplace the spring
Worn synchronizer clutch teeth or synchronizer ring gearReplace clutch or gear
Oil leak
Wear of oil seals of primary and secondary shaftsReplace seals
Loose fastening of gearbox housing covers, damage to gasketsTighten nuts or replace gaskets
Loose clutch housing to gearbox housingTighten nuts

Repair of the VAZ 2106 gearbox

The process of repairing the gearbox "six" is reduced to replacing broken or worn out elements. Considering that most of even the smallest parts of the box can be dismantled without problems, there is no point in restoring them. It is much easier to buy a new part and install it in place of the faulty one.

But in any case, requiring repair of the gearbox, it will need to be removed from the car and disassembled. It may take a whole day, or it may take more than one. Take this into account if you decide to repair the checkpoint yourself.

How to remove the gearbox

To dismantle the gearbox, you will need a lift, overpass or viewing hole. The presence of an assistant is also desirable. As for the tools, you will definitely need:

  • a hammer;
  • chisel;
  • passages;
  • keys for 13 (2 pcs);
  • key on 10;
  • key on 19;
  • hex key 12;
  • slotted screwdriver;
  • crosshead screwdriver;
  • mounting blade;
  • stop for supporting the gearbox during dismantling (special tripod, strong log, etc.);
  • container for collecting oil from the gearbox.

Dismantling procedure:

  1. We raise the car on a lift, or put it on a flyover, a viewing hole.
  2. We get under the car. We substitute a clean container under the gearbox drain plug.
  3. Unscrew the drain plug with a 12 hexagon. We are waiting for the grease to drain.
  4. We find the handbrake cable equalizer, remove the spring from it with the help of pliers.
    Design, repair and maintenance of the gearbox VAZ 2106
    The spring can be removed with pliers.
  5. We loosen the cable by unscrewing the two nuts with a 13 wrench.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the equalizer, unscrew the two nuts
  6. We remove the equalizer. We take the cable aside.
  7. On the cardan shaft and the flange of the gear of the main gear at the point of their connection with a hammer and a chisel, we put marks. This is necessary so that when installing the cardan not to disturb its centering. According to these labels, it will need to be installed.
    Design, repair and maintenance of the gearbox VAZ 2106
    Tags are necessary in order to put the cardan in the way it stood before dismantling
  8. We unscrew the nuts connecting the flanges with a key of 13 and disconnect them.
    Design, repair and maintenance of the gearbox VAZ 2106
    Nuts are unscrewed with a key of 13
  9. We bend the antennae for fixing the sealing clip with a thin slotted screwdriver, move it away from the elastic coupling.
    Design, repair and maintenance of the gearbox VAZ 2106
    The antennae of the clip must be bent with a screwdriver
  10. We dismantle the safety bracket by unscrewing the nuts securing it to the body.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the bracket, unscrew the nuts with a 13 wrench.
  11. We dismantle the cross member of the intermediate support by unscrewing the nuts with a 13 wrench.
    Design, repair and maintenance of the gearbox VAZ 2106
    The support nuts are unscrewed with a key of 13
  12. We shift the front part of the cardan, removing it from the splines of the elastic coupling.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the shaft from the coupling, it must be moved back
  13. We dismantle the cardan shaft.
  14. Let's go to the salon. Using a slotted screwdriver, remove the protective cover from the gearshift lever, disconnect the rings along the edge of the hole in the carpet.
    Design, repair and maintenance of the gearbox VAZ 2106
    Locking rings are removed with a screwdriver
  15. Using a screwdriver with a Phillips bit, unscrew the screws securing the cover.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the cover, you need to unscrew 4 screws
  16. Remove the cover.
  17. We disconnect the locking sleeve with a thin slotted screwdriver, slightly pressing the shift lever.
    Design, repair and maintenance of the gearbox VAZ 2106
    The sleeve is detached with a screwdriver
  18. We dismantle the lever.
  19. We pass to the engine compartment. We bend the eye-washer, leveling it with a hammer and a mounting blade.
  20. Using a 19 wrench, unscrew the box mounting bolt.
    Design, repair and maintenance of the gearbox VAZ 2106
    Before unscrewing the bolt, you need to unbend its eye washer
  21. We unscrew the two bolts fixing the starter with a key of 13.
  22. Using the same wrench, unscrew the lower starter fixing bolt.
    Design, repair and maintenance of the gearbox VAZ 2106
    To disconnect the starter, you need to unscrew 3 bolts with a key of 13
  23. We go down under the car. We unscrew the four bolts pressing the clutch starter cover.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the cover, unscrew 4 screws.
  24. Using pliers, unscrew the nut securing the speedometer cable.
  25. We put an emphasis to support the box. We ask the assistant to control the position of the checkpoint. Using a 19 wrench, unscrew all the crankcase mounting bolts (3 pcs).
    Design, repair and maintenance of the gearbox VAZ 2106
    When unscrewing the remaining bolts of the gearbox, it must be fixed
  26. We unscrew the two nuts of the gearbox cross member.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the cross member, unscrew the two nuts.
  27. Sliding the box back, remove it from the car.

Disassembly of the gearbox VAZ 2106

Before disassembling the gearbox, it is recommended to clean it from dirt, dust, oil leaks. In addition, make sure you have the following tools at hand:

  • two thin slotted screwdrivers;
  • impact screwdriver;
  • key on 13;
  • key on 10;
  • key on 22;
  • snap ring puller;
  • vise with workbench.

To disassemble the gearbox, you must:

  1. Using two screwdrivers, push the parts of the spacer to the sides, then remove it.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the bushing, you need to spread it to the sides of its sector
  2. Dismantle the flexible coupling together with the flange.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the coupling, unscrew the nuts with a 13 wrench.
  3. Remove the gearbox support by unscrewing its fastening nuts with a 13 wrench.
    Design, repair and maintenance of the gearbox VAZ 2106
    To disconnect the support, you need to unscrew the two nuts with a 13 wrench.
  4. Unscrew the nut on the speedometer drive mechanism using a 10 wrench.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the drive, you need to unscrew the nut with a 10 wrench.
  5. Remove the drive.
  6. Unscrew the reversing light switch using a 22 wrench. Remove it.
    Design, repair and maintenance of the gearbox VAZ 2106
    The switch is unscrewed with a key for 22
  7. Using a 13 wrench, unscrew the stopper of the gear lever.
    Design, repair and maintenance of the gearbox VAZ 2106
    The retainer bolt is unscrewed with a 13 wrench
  8. Remove the bracket by first unscrewing the 13-nut wrench.
    Design, repair and maintenance of the gearbox VAZ 2106
    Bracket secured with two bolts
  9. Using the same wrench, unscrew the nuts on the back cover. Disconnect the cover, remove the gasket.
    Design, repair and maintenance of the gearbox VAZ 2106
    A sealing gasket is installed between the crankcase and the cover
  10. Remove rear bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing can be easily removed from the shaft
  11. Remove the speedometer gear.
    Design, repair and maintenance of the gearbox VAZ 2106
    The gear is fixed with a small steel ball.
  12. Remove the reverse fork and idler gear.
    Design, repair and maintenance of the gearbox VAZ 2106
    The fork is fixed with a 10 mm nut.
  13. Disconnect the reverse speed split sleeve.
  14. Remove retaining ring and gear.
    Design, repair and maintenance of the gearbox VAZ 2106
    The gear is secured with a retaining ring
  15. Using a puller, remove the retaining ring on the output shaft, remove the driven gear.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the gear, you must remove the retaining ring
  16. Loosen the four bearing retaining plate screws. If the screws are soured, you may need an impact screwdriver to do this. Dismantle the plate, remove the axle.
    Design, repair and maintenance of the gearbox VAZ 2106
    Screws are best unscrewed with an impact screwdriver
  17. Using a 10 wrench, unscrew the nuts on the cover (10 pcs). Remove it, being careful not to tear the sealing gasket.
    Design, repair and maintenance of the gearbox VAZ 2106
    The cover is attached with 10 bolts.
  18. Disconnect the clutch housing from the gearbox by unscrewing the nuts using wrenches 13 and 17.
    Design, repair and maintenance of the gearbox VAZ 2106
    To disconnect the clutch housing, you will need keys for 13 and 17
  19. Using a 13 wrench, unscrew the clamp cover bolts. Detach cover.
    Design, repair and maintenance of the gearbox VAZ 2106
    The cover is attached with two screws.
  20. Remove the reverse gear shift rod.
    Design, repair and maintenance of the gearbox VAZ 2106
    The rod is simply removed from the crankcase
  21. Using a 10 wrench, remove the bolt holding the XNUMXrd and XNUMXth speed forks.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bolt is unscrewed with a key of 10
  22. Remove the stem and crackers of its blocking.
    Design, repair and maintenance of the gearbox VAZ 2106
    Together with the stem, the blocking crackers must also be removed.
  23. Remove the first and second speed rod from the gearbox.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the stem, you need to pull it towards you.
  24. Unscrew the bolt fixing the fork of the third and fourth stages.
  25. While pressing the couplings and using a 19 wrench, unscrew the bolt securing the front bearing to the intermediate shaft.
    Design, repair and maintenance of the gearbox VAZ 2106
    To unscrew the bolt, you need to turn on two gears at once by pressing the clutches
  26. Using two thin screwdrivers, remove the bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the bearing, you need to pry it with a screwdriver.
  27. Disconnect the rear bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the rear bearing, it must be pushed from the inside
  28. Remove intermediate shaft.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the shaft, it must be lifted from the back.
  29. Remove the shift forks.
    Design, repair and maintenance of the gearbox VAZ 2106
    The forks are mounted on the secondary shaft
  30. Pull out the input shaft with bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    The input shaft is removed together with the bearing
  31. Take out the needle bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing is mounted on the secondary shaft
  32. Use a screwdriver to remove the locking key on the back of the output shaft.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing is secured with a key
  33. Remove the rear bearing.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing is removed from the socket using thin screwdrivers.
  34. Pull out the output shaft.
  35. Clamp it in a vice and disconnect the synchronizer clutch, which includes third and fourth gears.
    Design, repair and maintenance of the gearbox VAZ 2106
    Before removing the coupling, the shaft must be installed vertically, clamped in a vice
  36. Remove the fixing ring with a puller.
  37. Remove the synchronizer hub.
    Design, repair and maintenance of the gearbox VAZ 2106
    To dismantle the hub, you need to remove the retaining ring
  38. Remove the next retaining ring.
  39. Disconnect the third gear.
    Design, repair and maintenance of the gearbox VAZ 2106
    The gear is fixed with a retaining ring
  40. Rest the first speed gear in an open vise and knock out the secondary shaft from it with a hammer.
    Design, repair and maintenance of the gearbox VAZ 2106
    The gear is knocked off the shaft with a hammer and a soft metal spacer.
  41. After that, remove the second speed gear, clutch, hub, and also the first speed bushing.
  42. Disassemble the synchronizer mechanisms of the first, second and fourth stages in the same way.
  43. Unclip and remove retaining ring on input shaft.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing is fixed with a circlip
  44. Place the bearing in a vise and drive the shaft out of it.
  45. Remove the gearshift lever by disconnecting the return spring and unscrewing the fastening nuts.
    Design, repair and maintenance of the gearbox VAZ 2106
    The lever is held by a return spring.

If faulty gears, synchronizers and forks are found during the disassembly of the gearbox, they should be replaced immediately. Defective parts should be considered parts that have visible signs of wear or damage.

Learn about the repair of the vacuum brake booster VAZ-2106: https://bumper.guru/klassicheskie-modeli-vaz/tormoza/vakuumnyy-usilitel-tormozov-vaz-2106.html

Video: dismantling the gearbox VAZ 2106

Disassembly of the gearbox vaz 2101-2107 5st

Bearing replacement

If, when disassembling the gearbox, it is found that one of the shaft bearings has play or visible damage, it will need to be replaced. All bearings in the VAZ 2106 gearbox have a non-separable design, so there can be no talk of any repair or restoration here.

In the gearbox, the rear bearings of the primary and secondary shafts are subjected to the greatest load. They are the ones that fail the most.

Replacing the input shaft bearing

If the gearbox is already disassembled and the input shaft assembly with the bearing is removed, simply knock it off the shaft with a hammer. Pack the new bearing in the same way. Usually, there is no problem with this.

There is another option for replacing the bearing without completely disassembling the box. It is suitable when you are sure that the rear shaft bearing is defective. Let's consider it in more detail.

Work order:

  1. Remove the gearbox from the car.
  2. Follow steps 1–18 of the previous instructions.
  3. Remove outer and inner circlips.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing is fixed with inner and outer circlips
  4. Pull the shaft towards you, pushing it out of the crankcase.
  5. Insert the slot of a large screwdriver into the groove of the bearing and fix it as firmly as possible in this position.
    Design, repair and maintenance of the gearbox VAZ 2106
    The bearing must be fixed by inserting a screwdriver into its groove
  6. While holding the outer race with a screwdriver, apply light blows to the shaft until the bearing comes off it.
  7. Slide the new bearing onto the shaft.
  8. Move it to its seat.
  9. Using a hammer, press in the bearing, applying light blows to its inner race.
    Design, repair and maintenance of the gearbox VAZ 2106
    To install a new bearing, it must be filled with a hammer, applying light blows to the inner race
  10. Install retaining rings.

How to choose input shaft bearing

In order not to make a mistake in choosing a bearing, it is important to know its parameters. We need an open radial type ball bearing of the sixth accuracy class. Domestic enterprises produce such parts under catalog numbers 6-50706AU and 6-180502K1US9. All products of this type must be manufactured in accordance with the requirements of GOST 520–211.

Table: main characteristics of bearings 6-50706AU and 6-180502K1US9

ParametersThe values
Outer diameter, mm75
Internal diameter, mm30
Height, mm19
Number of balls, pcs7
Ball diameter, mm14,29
steel gradeShKh-15
Load capacity static/dynamic, kN17,8/32,8
Rated operating speed, rpm10000
Mass, g400

Replacing the rear output shaft bearing

The output shaft bearing can be removed and installed only with the gearbox disassembled. To do this, it is necessary to perform the work provided for in paragraphs 1–33 of the instructions for disassembling the gearbox. After dismantling the bearing, a new one is installed in its place, after which the gearbox is assembled. It does not require any special tools to remove or install, nor does it require physical strength.

Choice of output shaft bearing

As in the previous case, when choosing the rear output shaft bearing, it is important not to make a mistake with the markings and parameters. In Russia, such parts are produced under the article 6–205 KU. It is also a radial type ball bearing. They are manufactured according to the requirements of GOST 8338–75.

Read also about the steering gear device: https://bumper.guru/klassicheskie-modeli-vaz/rulevoe-upravlenie/regulirovka-rulevoy-kolonki-vaz-2106.html

Table: main characteristics of the bearing 6–205 KU

ParametersThe values
Outer diameter, mm52
Internal diameter, mm25
Height, mm15
Number of balls, pcs9
Ball diameter, mm7,938
steel gradeShKh-15
Load capacity static/dynamic, kN6,95/14,0
Mass, g129

Replacing the oil seals of the primary and secondary shafts

Oil seals (cuffs) in the gearbox serve to prevent leakage of lubricant. If oil leaks from under the shaft, in most cases the oil seal is to blame. And it needs to be replaced. To replace the oil seals of the primary and secondary shafts, you will need to remove the gearbox. Of the tools you will need a hammer, punch, pliers and a cylindrical mandrel with a diameter equal to the diameter of the metal body of the cuff.

The shaft seal is pressed into the seat of the front crankcase cover of the box. When it is disconnected from the crankcase, it is necessary:

  1. Rest the end of the punch against the metal body of the stuffing box on the outside of the cover.
  2. Apply several blows with a hammer on the drift, moving it along the circumference of the stuffing box body.
    Design, repair and maintenance of the gearbox VAZ 2106
    The old seal is removed by knocking out
  3. On the reverse side of the cover, grab the cuff with pliers and remove it from the seat.
    Design, repair and maintenance of the gearbox VAZ 2106
    On the reverse side of the cover, the stuffing box is picked up by pliers
  4. Install a new cuff, lubricating it with grease.
  5. Using a mandrel and a hammer, press it into the socket of the cover.

To replace the output shaft seal, you will need pliers with thin ends, a hammer and a mandrel that matches the size of the cuff.

Complete disassembly of the gearbox is not needed here. It is enough to remove the elastic coupling and tear off the flange connecting it to the cardan from the splines of the shaft.

After that follows:

  1. Pry the cuff behind the metal case with a screwdriver.
  2. Remove cuff.
    Design, repair and maintenance of the gearbox VAZ 2106
    The cuff can be easily removed with a screwdriver
  3. Lubricate the new seal with grease.
  4. Install the cuff into the seat.
  5. Press in the cuff with a hammer and mandrel.
    Design, repair and maintenance of the gearbox VAZ 2106
    The gland is pressed in with a mandrel and a hammer

The choice of oil seals of the primary and secondary shafts

For the correct choice of oil seals, it is desirable to know their catalog numbers and sizes. All of them are presented in the table.

Table: catalog numbers and sizes of oil seals

Primary shaftSecondary shaft
Catalog number2101 – 1701043 Feet2101 – 1701210 Feet
Inner diameter, mm2832
Outside diameter, mm4756
Height, mm810

Gearbox oil VAZ 2106

The coordinated work of the gearbox elements depends on the quality of the lubricant washing them, as well as on its volume. The oil in the VAZ 2106 gearbox must be changed every 50 thousand kilometers. At least that's what the manufacturer says. But you need to check the lubrication level at least once a quarter.

What kind of oil to pour into the VAZ 2106 gearbox

In accordance with the requirements of the plant, only gear oil from groups GL-2106 or GL-4 according to API classification should be poured into the VAZ 5 gearbox. As for the viscosity class, oils of the following SAE classes are suitable:

The required amount of oil for a four-speed gearbox is 1,35 liters, for a five-speed gearbox - 1,6 liters.

Checking the oil level in the gearbox

To find out what level of lubricant is in the box, the car must be driven onto a horizontal overpass or inspection hole. The engine must be cold. The oil level in the gearbox is determined by unscrewing the oil filler plug. It is unscrewed with a key of 17. If oil pours out of the hole, everything is in order with the level. Otherwise, it must be topped up. But there is one nuance here. You can add oil only of the class and type that is already filled in the box. If you do not know what kind of lubricant is in the gearbox, it must be drained completely, and only then fill in a new one.

Draining oil from the gearbox VAZ 2106

To drain the grease from the "six" box, the machine must be installed on a flyover or pit. The engine must be hot. So the oil will drain faster and in full.

The oil drain plug is located in the lower crankcase cover. It is unscrewed with a key of 17. Before unscrewing it, it is necessary to substitute a container under the hole to collect the oil. When the grease drains, the plug is screwed back.

How and with what to fill oil in the checkpoint VAZ 2106

To fill the oil in the six gearbox, you will need a special syringe or a thin hose (must go into the oil filler hole) with a funnel. In the first case, the lubricant is drawn from the container into the syringe, and then squeezed out of it into the filler hole. The process continues until the lubricant flows out of it. After that, the oil filler hole is twisted.

When using a hose and a funnel, you need to insert one end of it into the hole, and raise the other at least half a meter above it. Grease is poured into a funnel inserted into the other end of the hose. When the oil starts to flow out of the box, the filling should be stopped, the hose removed, and the plug screwed on.

Kulisa KPP VAZ 2106

The backstage is a gear shifting device, which includes:

Removal, disassembly and installation of the backstage

To dismantle and disassemble the backstage, you must:

  1. Dismantle the transmission.
  2. Using a 10 wrench, unscrew the three nuts holding the backstage ball joint.
  3. Pull the lever towards you to disengage the device from the gear shift rods.
  4. Remove cuff and protective cover.
    Design, repair and maintenance of the gearbox VAZ 2106
    Protective case made of soft rubber
  5. Using a 10 wrench, unscrew the nuts on the guide plate.
    Design, repair and maintenance of the gearbox VAZ 2106
    The plate is fixed with three nuts
  6. Remove blocking plate.
  7. Use a screwdriver to pry the guide pads, remove them together with the springs from the guide plate.
    Design, repair and maintenance of the gearbox VAZ 2106
    To remove the pads, you need to pry them with a screwdriver
  8. Disconnect the plate together with the washer. Disconnect the flange with gasket from the lever.
  9. Remove the retaining ring with pliers, and then the thrust ring with a spring.
  10. Dismantle the ball joint.
    Design, repair and maintenance of the gearbox VAZ 2106
    The ball joint must always be lubricated

If wear or damage is found to parts of the backstage, they must be replaced. The assembly and installation of the backstage is carried out in the reverse order. The backstage of the VAZ 2106 checkpoint does not require adjustment.

Of course, the design of the VAZ 2106 gearbox is quite complicated, but if you wish, you can deal with it. If you think that you will not be able to carry out its repair on your own, it is better to entrust this matter to professionals. Well, as for the service, then you certainly can handle it yourself.

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