Replacing the clutch of a VAZ 21099 injector with your own hands

Adjusting and replacing the clutch on a VAZ 21099 car

Clutch disc assembly
The clutch is one of the components of a car's transmission. When this system breaks down, further movement becomes difficult, sometimes the car stalls, and sometimes it simply does not move when you press the accelerator pedal. Let's look at how to diagnose and replace clutch elements of a VAZ 21099 car with your own hands.

Clutch system failures are felt instantly, here is a list of the main symptoms.

When driving uphill, when you press the gas pedal, the car does not move, despite the ever-increasing engine speed.
When driving in a straight line, acceleration time increases significantly, the engine often overheats, and fuel consumption increases.
When stopping, pressing the brake and clutch pedals simultaneously will stall the engine.
It is difficult and crunching to switch gears on and off when the car is moving. When the engine is off, they switch without difficulty.
In the morning, when you try to start the car, the starter has difficulty turning the flywheel, despite the clutch pedal being depressed, and after starting, the engine runs hard and stalls after a while.
There is a noise when you press the pedal.
When changing gears, the car makes a jerk, and sometimes the engine stalls after it.
The clutch release pedal is difficult to press.
Full pedal travel exceeds 16 cm.

Causes and troubleshooting

Installing the disk on the machine

Symptoms 1 and 2 indicate critical wear of the clutch driven disc or contamination of it with engine oil that has leaked from the cylinder block or gearbox due to leaky seals of these units. To more accurately determine the cause, just look into the engine compartment and look through the window on the clutch housing cover. If there are traces of oil on the flywheel teeth, then the seals will have to be replaced. If there are no traces of oil, the clutch driven disc needs to be replaced.

Symptoms 3, 4 and 5 indicate incomplete shutdown of the mechanism. This occurs when drive parts break, driven and pressure disks are deformed, the cable breaks and the VAZ clutch drive is incorrectly adjusted.

Symptom 6 indicates a breakdown of the damper springs or wear of the release bearing. Symptom 7 indicates that the wheel hubs are jammed on the gearbox shaft splines. They just need to be removed, cleaned and lubricated. Symptoms 8 and 9 indicate that the cable needs to be replaced and the drive adjusted. Replacing the clutch assembly is also carried out after purchasing a used car.

Adjusting the VAZ 21099 clutch drive is a very simple procedure, it is done like this.

First you need to take a ruler and measure the distance the pedal moves when pressed. If it is less than 12.5 or more than 13.5 cm, we proceed to adjustment.
We look into the engine compartment, remove the battery, find the place where the cable passes through the gearbox bracket (next to the ignition coil). It is secured with adjusting nuts on both sides of the bracket.
If we need to increase the pedal travel, turn the nut located clockwise, located closer to the car interior. If, on the contrary, it is necessary to reduce the stroke, turn clockwise the nut that is closer to the front bumper.
Again, measure the distance with a ruler: if it is within the recommended limits, the adjustment is complete.

Replacing the cable is also not a very difficult task.

Open the hood and unscrew the adjusting nuts.
Remove the cable from the gearbox bracket.
Remove it from the clutch fork.
We move into the interior, knock the lock washer off the pedal pin and remove the cable end.
We take out the rubber gasket from the front panel from the side of the engine compartment and take the tip out.

The cable has been removed, now we install the new one in the reverse order. After installation, adjustment is required again.

Let's summarize

If the check shows that the free play is normal, but you doubt your competence in adjusting the unit, contact a service station. Incorrect settings can cause rapid clutch failure. If you want to complete the work yourself, you can find the necessary information on the vehicle manufacturer’s website or in its service book. It is important to complete the work in a timely manner so as not to get into an unpleasant situation on the road. Monitor the service life of clutch parts; for example, the service life of the driven disc is 100 thousand kilometers. But, if a motorist has an aggressive driving style, it can decrease by 2-3 times. How to replace a VAZ 21099 clutch, watch this video:

Source

Complex procedures

Replacing the clutch on a VAZ 2108-21099 is a labor-intensive and time-consuming process. To do this, you first need to remove the gearbox. After the gearbox is removed, you can proceed to the following operations.

Replacing the clutch cable

Replacing the fork and release bearing.

Using a screwdriver, remove the protective cover of the plug.
Unscrew the bolts securing the clutch basket and remove it.
Use a screwdriver to press the spring off the release bearing clutch legs.
We remove the bearing.
We remove the spring.
Unscrew the 3 bolts and remove the bearing guide sleeve.
Use a screwdriver to grab the special protrusion and remove the plastic bushing of the fork.
We remove the fork axle from the support sleeve and remove it from the basket.

Disassembly is complete, now we install new parts in the reverse order. When installing, it is necessary to lubricate the fork bushings with CV joint-4 grease.

First, remove the basket and lock the flywheel.
Unscrew the 6 bolts securing the casing to the flywheel.
Carefully remove the clutch cover along with the driven disc, holding it with your hand.
We inspect all parts for cracks and wear. We replace defective parts.
We put everything back together in reverse order.

Order of Operations

To carry out repair work, you need to place the car on an inspection hole, put it on the handbrake, disconnect the negative terminal to de-energize the on-board network, and remove the engine mudguard. Now you can start disassembling:

Install a jack that will temporarily replace the front pair of wheels. You need to unscrew the nuts on them, remove the chassis and put them aside.
To remove the contact part of the ball joint from the hub, you need to unscrew the bolts.
Instead of the 2 upper conventional bolts, you need to install cylinder head fasteners.

Now you can remove the starter; it is attached to three nuts that need to be unscrewed.

At this stage it is necessary to install a jack under the engine. After this, the side motor support is detached.

After this, you can disconnect the rear engine mount and unscrew the gearshift linkage.

The protective cover must be removed from the clutch.

The box is secured with several bolts; first you need to unscrew the front one.
Now the transmission is accessible, the rear nut is unscrewed first.
The gearbox bolts are located on the left wing side; they need to be unscrewed until they stop and the gearbox should be removed. It is important to ensure that the end of the assembly rests on the lever extension. This will create a gap that will allow you to remove the clutch. IMG9
Disassembly is complete. At this point, the guide for the clutch remains. It needs to be thoroughly lubricated. After this, you can put the release bearing on the guide.
Subsequent operations are performed in the reverse order of the above steps. Important! There is no need to rush while completing the work. All operations are performed consistently and calmly. Make sure that after assembly there are no “extra” spare parts left.

How to change the clutch on a VAZ 21099?

The clutch is one of the most important parts of a car. Without it, the car will not be able to move. That is why replacing the clutch on your vehicle is a procedure that needs to be taken very seriously.

This article is intended for those who prefer to repair their car themselves. Fortunately, the VAZ 21099 has a simple design and any car owner can replace the clutch on their own if they have the necessary tools and detailed instructions. In this article we will figure out how to change the clutch disc on a VAZ 21099 even without using a pit.

Signs of a malfunctioning clutch system

When a car is driven on a road with an incline, the car does not climb up the road, despite the car's engine speed constantly rising.
Increased speed when driving in a straight line, increased fuel consumption, engine overheating, increased fuel consumption.
If you press the clutch and brake pedal, the engine will stall.
If the engine is running, it is quite difficult to change gears. Such problems do not arise with the engine turned off.
During a cold start, it is difficult for the starter to turn the flywheel, although the clutch is intact. It is also difficult for the engine to run and stalls.
When you press the clutch pedal, extraneous sounds may occur.
When changing gears, the car may jerk or the engine may stall.
Depressing the clutch pedal may be difficult.
The clutch pedal travel exceeds normal (14 centimeters).

These causes indicate too much wear on the clutch disc or contamination of the working surface with oil. Inspect the disc as well as the flywheel. If they have traces of oil, the seals need to be replaced. If you do not see any traces of oil, be sure to replace the clutch driven disc with a new one.

All steps from start to finish

Open the hood and find the gearbox. The starter will be located nearby. All nodes are covered with a filter that needs to be removed:

Disconnect the negative terminal of the battery (key “10”);
We disconnect in turn: the mass air flow sensor connector (oval), the adsorber valve (we press the tongue from below). We also loosen and remove the fastening tie for the “thick wire”;

Getting rid of unnecessary details

A “fork” will be attached to the top of the crankcase - a bent plate with a slot. This is the clutch fork (see photo).

Found the most important detail

Using pliers wrapped in electrical tape, try to pull the tip forward.

Clutch adjustment on Lada Granta (first method)

Here we will look at how to adjust the clutch on a Lada Grant:

Grasping the end of the cable, pull it forward as far as it will go.
Using a caliper, measure the distance from the fork to the plastic leash. The distance should be exactly 27 mm.

If everything is set up and checked, measure the clutch pedal travel.

We measure the free movement distance

The distance from the “top point” to the “bottom” should not exceed 146 mm.

Alternative clutch adjustment method (second method)

No calipers are needed here:

Carry out step 1 as indicated above - pull the tip forward.
Let go of the tip and look: if the leash does not fit tightly to the fork, screw it onto the rod.
Press and release the pedal (3 times), repeat steps 1 and 2.

Achieve the following: when the pedal is not pressed, the leash should be pressed tightly against the metal, at the same time, the displacement of the fork should not be noticeable. Let the displacement be equal to 1-2 mm.

How to change a clutch disc

The clutch replacement process is quite lengthy, so you need to stock up on time and patience.

To replace the clutch, you must first remove the gearbox.

First of all, remove the crankcase protection and unscrew the gearbox mounting bolts.
Remove the negative wire from the clutch housing.
Using two wrenches, remove the clutch cable from its bracket.
Disconnect the block from the wire from the starter contact.
Remove the starter from the gearbox by unscrewing the three nuts.
Remove the gear shift system drive end.
Disconnect the speedometer and gearbox drive cables.
Remove the contact with a wire from the reverse indicator switch block.
Loosen the nut securing the arm to the suspension.
Unscrew the three bolts that secure the braces to the body.
Remove the ball joint nut cotter pin.
Remove the ball joint.
Remove the CV joints. Pull them aside.
Unscrew the bolts that secure the clutch shield and also dismantle it.
Unscrew the three bolts and the crankcase mounting nuts.
Install suitable wooden beams on the fenders and place a block on top to hang the engine.
The block should rest on the bars and nothing else.
Attach the engine to a block that has a bolt with a hook. For this procedure, it is allowed to use rope or wire.
Unscrew a couple of nuts securing the rear engine support to the body.
Unscrew the nuts securing the engine to the gearbox.
When removing the gearbox, first move the gearbox horizontally, otherwise the input shaft may be damaged.

Please note that this method is the most convenient, since it can be used to remove the gearbox without a hoist or hoist. This may only require a couple of jacks.

Replacement

Not all car owners decide to replace the release bearing (TR) themselves. But if you are ready for this kind of work, then go for it.

VI components

Therefore, think twice before making a final decision. There is always the opportunity to contact a car service.

To work you will need the following set of tools and materials:

Set of wrenches;
Jack;
Several durable bricks;
New release bearing;
Screwdriver Set;
Container for draining transmission fluid;
Clutch holder;
Garage with a pit or lifting mechanism.

It is better to divide the entire replacement procedure into two main stages.

Removing the gearbox.
Bearing replacement.

Many people make the mistake of relaxing too much when they finally change the bearing. In practice, reassembly often causes more problems than dismantling work. Please take this into account.

Dismantling the gearbox

Place the car over a hole or overpass.
Lift the hood, remove the negative terminal from the battery and throw it aside.
Disconnect the ground wire from the clutch housing.
Use a screwdriver to remove the engine splash guard. To do this, you need to unscrew several screws that hold the mudguard to the elements of the side wings. For the VAZ 2109, a key size of 8 is used. Having removed all the screws there, remove the parts of the engine mudguard and put them away for now.
Disconnect the transmission drive rod. To do this, use a 13mm wrench to loosen the clamp bolts. Next, use a screwdriver to separate the ends of the clamp and disconnect the element from the gearbox.
Be sure to disable the reverse optics sensor.
Place blocks or bricks under the rear wheels of the car to prevent the car from moving.
Remove the front wheels by first loosening the bolts and lifting the front part of the body. After removing the wheels, place pre-prepared bricks under the body.
Using a 17 wrench, unscrew the nuts securing the ball joint to the steering knuckle on both sides.
The extension is moved to the side, and the fastening screws of the left extension to the vehicle's suspension arm are unscrewed.
Using a 10 mm wrench, remove the fasteners of the lower clutch housing cover.
Remove the transmission mounts. This is done as follows. Place supports or bricks under the engine and a jack under the box. Unscrew the mounting screws of the support to the body with a 17mm wrench. After removing the bolt, remove the support bracket by unscrewing several corresponding nuts.
We proceed directly to dismantling the gearbox. Using a 19 wrench, unscrew the fasteners of the clutch housing to the cylinder block. Use a jack to lower the gearbox slightly and move it away from the engine. Lower until the input shaft begins to come out of the box.
Enlist the support of a partner, since it is quite difficult to remove the gearbox alone.
Make sure that the gearbox input shaft does not rest on the clutch spring petals. If you allow this situation to happen, you will simply damage them.
Carefully place the gearbox on the supports, being careful not to hit it. Otherwise, repairs will cost much more than buying a new bearing.

How to install the clutch disc correctly

Remove the six bolts from the clutch basket using an eight-millimeter wrench. Be careful not to strip the bolt heads.
Remove the clutch cover along with the driven disc.
Check its condition. The driven disk must be free of cracks and deformations. Otherwise it needs to be replaced.
Check the working part of the flywheel and release mechanism. They must be free of chips, burrs and deep marks. If there are such deformations, then the flywheel and release mechanism need to be replaced.

After inspection, you need to assemble the clutch disc. Pay attention to how to correctly install the clutch disc:

It is installed in the opposite order, but the less protruding part should face the flywheel.

Also, when installing a new clutch disc, it is better to use a centering mandrel. If it is not included in the kit, then purchase it. Fortunately, it is not expensive at all.

Source

Clutch selection

Why the clutch slips: reasons, do-it-yourself adjustment
When choosing a clutch kit, you should focus not only on your available budget. By saving or buying a fake, you risk getting even more problems in the future.

Valeo kit

Today there are several main manufacturers whose clutches should be purchased for the VAZ 2109.

Manufacturer

Peculiarities

VIS

This is a stock clutch that the VAZ 2109 is equipped with from the factory. If there are laser markings on the discs, this is definitely not a fake. Plus, the company allows you to send an SMS indicating an identification code. If it is a fake, you will be notified accordingly. Good quality, but nothing special to say about them

Valeo

French manufacturer, which is actively counterfeited on the domestic market

To catch fraud, pay attention to the cost and quality of components. Although the brand is from France, Valeo couplings can be produced in Italy, Spain, South Korea

Good quality components ensuring smooth, easy operation. Perfect for female drivers. If you use the clutch correctly, it will last for about 150 thousand kilometers. The flywheel is almost eternal, and the disks are not afraid of overheating within acceptable limits

Luk

A German company that has proven itself well in its homeland and has also earned a lot of praise among Russian motorists. They dampen vibrations perfectly, and real Luk clutches always have an element for damping vibrations of the pressure and driven disks.

Kraft

You can only find negative reviews about Kraft couplings from competitors. An impressive part of the sets under the Kraft brand, presented in Russia, were produced in Turkey, but under a German license. The kit includes a soft release bearing that performs well even under heavy use. The flywheel is very durable. On average, the clutch can withstand 150 thousand kilometers. But if you don’t spare the clutch, the life will be significantly reduced.

Kraft kit

Regardless of the quality of the selected kit, if it is installed incorrectly or due to rough operation of the vehicle, the life of the clutch will not be able to reach those declared by the manufacturer. Therefore, drive your car accordingly.

Signs and causes of clutch failure

The VAZ 2108, 2109, 21099 clutch consists of a basket, a pressure bearing, a drive and driven disk. The main signs of a clutch malfunction are clutch slipping and incomplete disengagement:

When switching off is incomplete (the pedal is pressed), there is difficulty shifting gears with the engine running, noise and crackling noises when changing gears, and large free play of the clutch pedal.
When the clutch “slips” (the pedal is released), a burning smell may be felt in the cabin from the burning of the clutch disc linings, the car’s dynamics will deteriorate, the engine may overheat, and fuel consumption will increase.

In addition to the clutch disc itself, the release bearing can also fail - it serves to smoothly engage and disengage the clutch. When the release bearing wears out to the limit, you can hear a characteristic squealing sound - this is a sure sign that the bearing needs to be replaced. The cause of clutch failure may also be a breakdown in its drive mechanism, for example, a break or jamming of the clutch drive cable, a breakdown of the lever system, a fluid leak from the hydraulic drive if the clutch is hydraulic, or other similar breakdowns in the drive.

By the way, when replacing the release bearing at a service station, they may advise you to also replace the clutch disc. Usually, if problems begin with the clutch, it is better to replace all these parts, because replacing the clutch is very difficult: you need to remove the gearbox. But if someone wants to save on this, then all clutch parts can be purchased separately.

To work you will need the following:

wrenches 8, 10, 13, 17 mm;
torque wrench, 8 mm socket;
jack;
container for draining oil;
inspection hole or lift.
flat screwdriver, hammer.

Symptoms of malfunction

The clutch release bearing itself will tell you that its life is already at its limit or it has completely failed. Therefore, your task is to monitor the behavior of the car and promptly respond to emerging problems.

Sign of breakdown

Peculiarities

The clutch pedal becomes hard to press

Initially, this only causes a certain discomfort, since you have to apply more force to change gears. But this phenomenon should not be ignored. Bearing needs to be replaced

Difficulty engaging first and reverse gears

This indicates that the bearing's life is gradually ending, and you urgently need to take action. If you don't do this, you will soon be unable to engage any of the gears in your transmission.

The car doesn't pull

There is a loss of efficiency and performance of the box. Consequently, it is not possible to change gears correctly and quickly. This makes maneuvers, overtaking and a banal increase in speed more difficult.

This happens occasionally at first, and therefore almost every time you change gears. This symptom clearly indicates that it is time to send the car to a service station or garage for repairs.

Old and new VP

If the release bearing is not replaced in a timely manner, the gearbox will soon fail, the clutch will not work, and this will lead to dire consequences.

Consequences of wear

If you have encountered such a phenomenon as wear of the clutch release bearing, then you probably often drive your own VAZ 2109. It is time and the many kilometers traveled that lead to such breakdowns.

If the bearing is not replaced in time, this will result in the following consequences:

Any subsequent trip may be the last for the car;
The clutch disc will overheat, which will lead to destruction of the lining;
In addition to replacing the bearing, you will have to replace the entire clutch disc;
It is not uncommon for the clutch to fail. If you hear an incomprehensible noise coming from the clutch system, then there is a problem with it.

Replacing the clutch on a VAZ 2109/21099 without removing the gearbox

Replacing the VAZ 2109/21099 clutch without removing the gearbox is quite difficult. You will not find instructions or recommendations on this topic in the car's owner's manual. These recommendations are based on the experience of car enthusiasts who share their experience of replacing the clutch.

The main problem when replacing a clutch is that not every motorist has an overpass, a pit, and especially a lift, and it is necessary to make sure that the massive gearbox does not fall to the ground. But lifting it is problematic, since it is impossible to crawl under the car with it. All steps for removing the gearbox are almost the same as the instructions above, with the exception of some nuances:

Purchase two bolts from the upper arm of the classic front suspension from the store. Their threads are exactly the same as those on the bolts that secure the box and the engine block together.
Screw them in from above, only after that, with a small crowbar or screwdriver, we begin to disconnect the nodes. After moving away, the rear part of the box will rest on the transverse rod, and a gap of about 15 centimeters will form between the clutch housing and the flywheel.
The release bearing is removed through the resulting gap and the bolts on the basket are unscrewed.