How to remove the gearbox
To remove the gearbox from a Lada Kalina car, you need to be able to hang the car. A lift is best, but an overpass or a pit in a garage will do. You will need a set of tools in the form of keys, sockets, flathead screwdrivers, and pliers. Since the oil will have to be drained, you need a container for used oil with a volume of 4-5 liters, new oil and gloves. The box itself is quite heavy, ask someone to help you.
Pit in a garage or car service
If you are an experienced motorist, removing the box on a Kalina will not be difficult for you. The main thing is to follow safety precautions and instructions.
Hanging the car
First, drive the car onto a pit, lift or overpass, then secure it with the handbrake and put the car in gear. It doesn't hurt to put something under the wheels to prevent the car from rolling. Check if it is securely fastened. If it rolls away, it can cause serious injury and expense if it becomes damaged.
Disconnecting wires and battery
When the ignition is turned off and the car is locked, disconnect the battery by first removing the negative and then the positive terminal. From the box there are plugs with wires for the reverse lights, a locking solenoid and a speed sensor. They also need to be disabled. Don't forget to disconnect the starter.
Oil drain
Prepare an empty waste oil container and gloves. Contact of old oil with skin is extremely undesirable due to toxicity. The container itself should be 4-5 liters in volume.
Unscrew the oil filler neck of the box and then the drain plug. This is done so that the oil comes out faster and more evenly. The draining procedure will take about half an hour, during which time prepare all the necessary tools.
When installing, remember that the oil must be filled with the same brand. If you want to fill in something else, rinse the system with flushing oil and fill in with fresh oil. When replacing, it is better to change the O-ring to avoid leaks. It is inexpensive, there is no point in saving on it.
Dismantling the box
Removal procedure:
- The lower clutch housing cover is secured with 3 bolts. Unscrew them with a 10mm wrench and remove the cover.
- Remove both wheel drives. The gearbox control rod is tightened with a clamp. Loosen the nut with a 13mm wrench and disconnect the rod.
- The clutch housing is attached to the gearbox housing with two bolts. They need to be unscrewed with a 19 key.
- Remove the torque rod together with the bracket from the gearbox.
- The throttle drive cable is secured to a plastic clamp. Unplug it.
- Using the 13th head, unscrew the bolt securing the ignition coil to the clutch housing.
- Using the 19th head, unscrew the bolts securing the gearbox to the cylinder block and move the bracket to the side.
- Prepare wooden blocks and stops. Remove the left front suspension brace, support the engine crankcase and gearbox.
- The rear mounting of the gearbox to the cylinder block is secured with a nut. Unscrew it and do the same operation, but with the lower front gearbox mount.
- Unscrew the screws securing the front left power unit support bracket with the E-14 head.
- Unscrew the nuts securing the front left support of the power unit to the gearbox using the 15th socket. Remove the bracket.
- Using the 19th head, unscrew the two side bolts of the rear support bracket of the power unit to the transmission, and with the 17th head the bolt in the center.
- Move the gearbox away from the internal combustion engine so that the input shaft disengages from the clutch with the disc. The box is heavy, it is important to do this with an assistant.
- Carefully place the transmission on the floor.
Lada Kalina gearbox (source https://forum-wec.com/index.php?showtopic=289521)
The installation process is the reverse of its dismantling. When you install the transmission, fill in the same oil as before. If you fill in a new one, rinse it.
Choice
ATTENTION !. There are two types of clutch installed on the Lada Kalina:
- 190 mm (three bolts at the starter),
- 200 mm (two bolts at the starter).
You can tell exactly which one you have after analysis. We recommend doing just that. But you can tell by the starter, or rather by its mounting .
We installed VALEO 828003 . It cost about 3,500 rubles per set.
- LADA 21100-1601000-00
- Krafttech W05200G
The resource directly depends on the conditions of use of the equipment, but high-quality parts can last up to 100 thousand km.
If troubles arise on the road, it is recommended to have it towed or seek the services of a tow truck, since there is a risk of gearbox failure.
Repair, features and technical specifications
Inside a VAZ 21118 car, like any other, there is always a gearbox. For a model such as Kalina 1118, this device is a mechanical type design, which is equipped with one reverse stage, as well as 5 forward stages.
Gearbox from Lada Kalina.
In Lada Kalina, the gearbox is structurally combined with a differential, the main gear. Transmission differential repair should also take this into account.
The mechanism body of the VAZ Kalina car is presented in the form of three aluminum copper crankcases:
Special sealants are applied between them when assembling and repairing the gearbox.
Removal and installation of the gearbox
Servicing the gearbox assumes that the mechanism will have to be removed and its position changed. Before doing this, you need to install the vehicle itself on the lift. The ignition must be turned off completely and the parking brake must be used.
How to repair a gearbox? To do this, disconnect the minus terminal from the battery. The hood must be opened completely. Any manual on gearbox repairs writes about this.
The oil filler cap is also removed. It is necessary to install the previous item after the screen is removed. The gearbox requires loosening the clamp responsible for fixing it. The inlet pipe hose must be disconnected from the corresponding sensor. Gearbox lever play requires the same actions in practice. Then you need to unscrew the air intake nut.
The repair progress further depends on the specific malfunction.
Gearbox Lada Kalina after dismantling and disassembly.
The gearbox can be installed in its original place after the 1st speed repair is completed. SHRUS-4 lubricant is applied to the outer surface of the corresponding bushing in the clutch in a very thin layer. This will also help if the gearbox is loose. The pin fixing bolts are removed from the steering knuckles.
Recommendations for the use of transmission oils for Kalina
Adding oil or replacing it in the Kalina gearbox will require an answer to the question of which substance to choose. It is better to build on the manufacturer's recommendations. The machine's operating manual provides a list of different oils. They are classified by:
- brand;
- viscosity grade (SAE);
- API group;
- to the manufacturer.
It is important which substance ensures stable operation of the gearbox in the widest temperature ranges. This is oil with viscosity marking 75W-90
It guarantees lubrication of components at temperatures from -40° to +45°.
Which gear oil has more universal properties? This can be considered a substance whose viscosity is designated 80W-85. If Kalina’s gearbox is filled with this oil, then normal operation of the units is maintained in climatic conditions from -26° to +35°.
Replacement algorithm
View of the engine compartment with the battery removed.
Disconnect the gearbox shift lever.
We tie the box to the crossbar so it doesn't fall.
We remove the wheel, lever and pull out the drive so that it becomes possible to move the box without draining the oil.
Engine support is required, since the mounting pads have been removed, and they are common to the engine and gearbox.
After pulling the box away, a gap is formed that allows you to remove the clutch basket.
Old clutch - the linings are gone and the disc is already rubbed with rivets.
Before installing new parts, lubricate the clutch fork.
For alignment we use a plastic bushing (some manufacturers include it in the clutch kit).
Even when the first signs of a clutch malfunction appear, it is recommended to start purchasing parts and prepare quickly to replace the entire set.
Minor problems are always easier and cheaper to fix than major repairs of components.
Symptoms of replacement
Mechanical damage can be seen only after removing the clutch from the car, but its wear can be understood by certain changes that have appeared in the operation of the mechanism.
The manufacturer recommends a complete replacement for the following symptoms:
Mechanical part
If the reverse gear on the Kalina does not engage, the reasons may be in the shift mechanism. The latter has a spring in its design. It breaks often. If the part “falls” to the bottom of the box, it will not interfere with gear shifting. The driver can drive like this for several years, not suspecting that a spring has fallen out of the mechanism.
But if it gets stuck in the grooves, reverse gear breakdowns will be inevitable. Depending on the position of the part, the speed may turn on periodically or not work at all. In this case, you will have to completely disassemble the gearbox and pull the stuck element out.
What tricks have they done with TsBKE?
Some time ago, the list of defects would have included the failure of the CBKE, that is, the body electronics unit. The firmware intended for the specified Grants/Kalina-2 unit has now been updated. As a result, we managed to get rid of the malfunction completely - the equipment itself cannot fail. But not everyone likes how the new firmware works - some owners experienced an incomprehensible defect when the reaction of the lamps to the actions of the warrior became “strange”. However, we have published a video where a corresponding example is given further, and you can evaluate the quality of the work of the Central Bank of the Russian Federation “live”.
In the “first Kalina”, by the way, electrical devices were controlled by individual elements (relays, toggle switches), each of which could theoretically fail, which would require its search and replacement. The design of "Kalina-2" is more modern, something is being updated in it, and the use of some components has to be abandoned. This was the case with the South Korean EUR. Now Russian amplifiers continue to be used.
Features of electrical equipment of Lada Kalina-2
Is it worth changing the bearings in AMT yourself?
AMT is a robotic gearbox that combines manual and automatic gearboxes. It is almost as reliable as a manual transmission, but costs more. Consumes less fuel and consumables than a “classic automatic”.
The disadvantages include the high cost of repairs. It is not recommended to change bearings in AMT yourself. Firstly, the structure of the box is much more complex, so a qualified specialist can repair the car. Secondly, the car needs to be reprogrammed for any changes, which is also inaccessible to the average car enthusiast.
