Possible malfunctions of a transmission and ways of their elimination  

Features of maintenance service of a transmission  

Transmission repair  

On cars "GAZELLES" the five-high-speed transmission is established. Weight (without refuelling) — 32 kg.

Presence of 5th raising transfer provides in actual practice operation economy of fuel of 0,7-1,0 l on 100 km of run in comparison with a four-high-speed transmission, the maximum speed of 115 km/hour, reduces engine turns on high speeds of movement of the car, raising its durability.

Fig. 5.13. The Transmission (longitudinal section): And — двухконусный the synchronizer; 1 — a primary shaft; 2 — a cover of the bearing of a primary shaft; 3 — an epiploon; 4 — the ball bearing of a primary shaft; 5 — a lock ring; 6 — the roller bearing of a secondary shaft; 7 — сапун; 8 — a blocking ring; 9 — муфта inclusions; 10 — a synchronizer cracker; 11 — a nave муфты inclusions of 3rd, 4th transfers; 12 — a gear wheel of 3rd transfer; 13 — the needle bearing of a gear wheel; 14 — a lock ring of half rings; 15 — a half ring; 16 — a gear wheel of the second transfer; 17 — a lock ring; 18 — a gear wheel of 1st transfer; 19 — a secondary shaft; 20 — a backing gear wheel; 21 — a plug of inclusion of 5th transfer and a backing; 22 — a nave муфты inclusions of 5th transfer and a backing; 23 — a bolt of fastening of a plate of a clamp; 24 — a plate; 25 — a spring of clamps; 26 — a ball of clamps; 27 — a spring of the blocking plug; 28 — the plug blocking; 29 — a head of a rod of inclusion of 5th transfer and a backing; 30 — the case of the lever of switching; 31 — a gear wheel of 5th transfer; 32 — a washer persistent; 33 — the plug распорная; 34 — картер transmissions back; 35 — an epiploon; 36 — an axis of an intermediate gear wheel of a backing; 37 — the needle bearing of an intermediate gear wheel of a backing; 38 — an intermediate gear wheel of a backing; 39 — a pin; 40 — a bolt of fastening of the plug of an axis of an intermediate gear wheel of a backing; 41 — the plug of an axis of an intermediate gear wheel of a backing; 42 — the ball bearing of a secondary shaft; 43 — a ring lock the bearing of a secondary shaft; 44 — a ring lock; 45 — the bearing; 46 — a stopper маслосливная; 47 — the block of gear wheels; 48 — a stopper маслоналивная; 49 — картер transmissions forward; 50 — adjusting linings

Carter of a transmission is made of an aluminium alloy and consists of two parts — forward 49 and back 34 картеров (fig. 5.13). Carters for maintenance necessary соосности support of shaft and apertures under rods of the mechanism of switching are aligned on adjusting plugs, запрессованным in forward картер, and incorporate with each other ten bolts.

The gear wheel of a primary shaft, and also gear wheel of 1st, 2nd, 3rd, 5th transfers and the backing, established on secondary to a shaft 19, are in constant gearing with gear wheels of the block of gear wheels 47, have slanting teeths and rotate on needle bearings with plastic separators. The intermediate gear wheel of a backing rotates on bulk rollers in diameter of 3 mm on an axis which support settle down in both картерах.

All transfers are supplied by synchronizers of the inertial type which gear wreaths incorporate to gear wheels by means of small шлицев. Synchronizers of 3rd, 4th, 5th transfers and a backing have the gear wreaths executed at the same time with cones. Alignment of turns of an included gear wheel necessary for an unaccented gear change to turns of a secondary shaft is reached by means of the brake moment arising at the expense of forces of a friction on an external surface of a cone of a gear wreath of a gear wheel and internal конусной of a surface of an external (blocking) ring of 8 synchronizers, connected through naves 11 and 22 with secondary shaft 19.

Fig. 5.14. The Dvuhkonusnyj synchronizer of 1st — 2nd transfers: 1 — муфта; 2 — a nave; 3 — a secondary shaft; 4 — a gear wheel; 5 — a synchronizer cracker; 7 — a gear wheel of 1st transfer; 8 — a ring internal; 9 — a ring an average; 10 — a gear wreath; 11 — a ring external

The synchronizer of 1st — 2nd transfers — двухконусный, has the increased brake moment at the expense of an additional surface of a friction, образуемой an external conic surface of the internal ring connected with a nave 8 (fig. 5.14) and an internal conic surface on an average ring 9 synchronizers, connected by three ledges (ledges enter into apertures on a gear wreath 10) with an included gear wheel.

It is necessary to notice that till 01.06.03 in a transmission it was established одноконусный the synchronizer unified with synchronizers of 3rd, 4th, 5th transfers and a backing. Inclusion of transfers is made by connection of internal teeths муфт 9 (fig. 5.13) with external gear wreaths of synchronizers. Lateral faces of teeths муфт and wreaths of synchronizers are cut inside at an angle 4 ° and at the included position form the lock interfering self-deenergizing of transfers. Ledges on teeths of wreaths of synchronizers limit movings муфт at inclusion of transfers.

Axial forces from slanting teeths of gear wheels of a secondary shaft are perceived by lock rings 17 and 44, a persistent washer 32, буртом a secondary shaft and located in a flute on secondary to a shaft two persistent half rings which are covered by a ring 14.

Ball bearings of primary and secondary shaft are established on shaft by means of spring and lock rings and fixed in картерах by means of external lock rings.

The block of gear wheels rotates on the ball or conic bearings established in deaf nests forward and back картеров.

Fig. 5.15. The gear change mechanism: 1 — forward картер; 2 — a plug of inclusion of 1st and 3rd transfers; 3 — a bolt of fastening of a plug of inclusion; 4 — a plug of inclusion of 1st and 2nd transfers; 5 — a rod of inclusion of 1st and 2nd transfers; 6 — a rod of inclusion of 3rd and 4th transfers; 7 — a finger; 8 — плунжер; 9 — a rod of inclusion of 5th transfer and a backing; 10 — a plug of inclusion of 5th transfer and a backing; 11 — a clamp ball; 12 — a clamp spring; 13 — a bolt of fastening of a plate; 14 — a plate; 15 — a spring of the blocking plug; 16 — the blocking plug; 17 — a head of a rod of inclusion of 5th transfer and a backing; 18 — the case of the lever of switching; 19 — the switching lever — the bottom part; 20 — запорная the plug; 21 — a rubber pillow; 22 — распорная the plug; 23 — a persistent cone; 24 — the switching lever — the top part; 25 — the handle of the lever of switching; 26 — a body floor sealant; 27 — a protective sealant; 28 — a saddle of a spring of the lever; 29 — a lever spring; 30 — a cap; 31 — a pin; 32 — a safety lock; 33 — a safety lock spring; 34 — a head of a rod of inclusion of 1st and 2nd transfers; 35 — a restrictive pin; 36 — back картер; 37 — the switch of light of a backing; 38 — a plug cracker

The pretightness is carried out by statement at assemblage of adjusting linings 50 in a nest forward картера. Wreaths of gear wheels of constant gearing of 2nd, 3rd and 5th transfers of the block of gear wheels are planted with a tightness on an intermediate shaft on which the long teeths serving simultaneously by wreaths of gear wheels of 1st transfer and a backing of the block of gear wheels are cut. The head of an axis 36 intermediate gear wheels of a backing is established in bed back картера transmissions and fastens in it a lock bolt. The opposite end of an axis enters into the plug 41, is fixed in it by a cutting elastic pin, the plug fastens to bed in forward картере also a lock bolt. The switching mechanism contains rods on which gear change and head 29 plugs in which grooves the bottom end of the lever of switching settles down fasten. Fixing of rods in the included and switched off position is carried out by means of balls 11 (fig. 5.15) and springs 15. The blocking device consisting from two lock плунжеров and lock fingers, protects a box from simultaneous inclusion of two transfers. Besides, between a head of a rod of inclusion of a backing and a wall back картера the blocking plug 16 with a spring 15 which does impossible casual moving of the lever of switching of position of included 5th transfer to backing position settles down. The gear change lever is supplied демпферным by the device eliminating its tinkling sound at a resonance on the big turns of the engine, and settles down in the special case 18 fastening to back картеру from above. By means of springs and safety locks the bottom head of the lever of switching in neutral position always settles down in a head of a rod of inclusion of 3rd and 4th transfers.

The masloslivnaja stopper 46 (fig. 5.13) has a magnet catching small parts containing in oil of metal — products of deterioration of details of a transmission.

Five-high-speed transmissions for cars "Volga" and cars "GAZELLES" are unified on the majority of details. The transmission of cars "GAZELLES" differs primary shaft (number of teeths 25 instead of 26), a mounted wreath of a drive of the block of gear wheels (36 teeths instead of 35) and a gear wheel of a drive of a speedometer, higher case of the lever of switching and the bottom part of the lever of a gear change.