The gearbox is considered to be a mechanism designed to change the frequencies and torques of the driving wheels within increased limits. A gearbox with a mechanical transmission is most often gear.
Manual transmission of modern domestic cars is a convenient and reliable unit that cannot avoid the prospect of wear or the impact of negative factors. Most often, motorists have to deal with the following gearbox malfunctions:
⦁ spontaneous shutdown of the lower gear of the box - the device uncontrollably returns to the neutral mode;
⦁ occurrence of an oil leak;
⦁ the appearance of extraneous sum, hum, grinding or vibration;
⦁ crumbling of bearing teeth;
⦁ bearing malfunctions or deformation of springs;
⦁ relaxation of chain tension.
All of the above negative factors are a direct result of long-term vehicle operation without proper maintenance. Aggressive driving style, which involves jerky gear changes and rough handling of the lever, can significantly accelerate the process of responsible wear of gearbox mechanisms. A reliable car service will allow not only to quickly identify the cause of the breakdown, but also to comprehensively fight to overcome it. Sale of a gearbox allows the motorist to radically get rid of problems - to buy a manual transmission and install a new mechanism.
Transmission faults usually develop as a result of:
⦁Significant wear of parts due to oil starvation of the gearbox.
⦁Long trips with the first axle engaged unnecessarily.
⦁ Abrupt and aggressive operation of the gearbox - jerky shifting or abrupt transition to neutral mode.
⦁Usage lubricants, which are incompatible with a certain manual transmission or are not intended at all for this mechanism.
⦁Unqualified maintenance - unauthorized gearbox bulkhead can cause poor-quality twisting of the mechanisms.
⦁ prolonged exposure to vibrations or loads as a result of inaccurate use of the gearbox.
⦁Installations of parts that are not compatible with a specific modification of the gearbox.
⦁Installation of used or non-original parts.
⦁Lack of regular gearbox diagnostics - it is worth checking the condition of the gearbox after overcoming the first 50,000 km of run.
⦁ Unprofessional vehicle maintenance.
Despite the fact that the gearbox is not considered a fragile mechanism, it needs careful and careful use and timely technical inspection. Early diagnosis of malfunctions and identification of their causes will allow the entire mechanism to continue its life due to the local replacement of worn parts.
Top 5 UAZ manual transmission malfunctions
In the process of active operation of the hardy modern car his systems wear out sooner or later. The motorist will have to say goodbye to bearings, synchronizers, oil seals, couplings, pumps, transfer cases, center differentials, gear forks, rods and others. constituent parts... At the same time, the choice remains with the owner himself: to re-buy the gearbox or locally replace the worn-out mechanisms to continue the service of the original gearbox.
The manual gearbox of a UAZ car usually encounters the following malfunctions:
⦁ Poor fastening of the gearbox to the crankcase - this negligence is fraught with spontaneous disengagement of the forward gear, which is especially dangerous under heavy shock loads. Loosening usually occurs during clutch replacement or oil refilling.
⦁ Sharpened synchroniser teeth that can cause jerky or difficult gear changes.
⦁Worn bearings and faulty rod retainers - these can cause spontaneous shutdown or gear shifting.
⦁Worn gear teeth, which can lead to problem shifting and the appearance of knocking or grinding noise during the mode changeover. This defect requires a comprehensive solution, the implementation of which is facilitated by the sale of manual transmissions. Installation new box will provide the teeth of the gears with uniform abrasion as a result of the planned load.
⦁Oil problems - this general group of faults is caused by the use of poor-quality lubricant, insufficient amount of oil or its non-compliance with a certain gearbox modification.
Despite the fact that most of the listed malfunctions can be promptly eliminated by a local method, qualified specialists of proven service stations still advise motorists not to crowd together and carry out a comprehensive replacement of worn out parts or even install a new gearbox.
A quality service station is characterized by:
⦁the presence of our own store with original spare parts and mechanisms - the sale of gearboxes allows the motorist to immediately abandon local repair in favor of a new mechanism;
⦁use of high-tech equipment;
⦁specialists with many years of practical experience;
⦁ high quality diagnostic equipment;
⦁possibilities for prompt and high-quality exchange, sale and installation of all modifications of gearboxes and other UAZ mechanisms.
Modern auto centers are a whole complex of maintenance, which provides disassembly, defecting, replacement or repair of boxes of all types, manufacturers and modifications.
Tools for dismantling UAZ gearboxes
Qualified transmission repair is based on a careful and well-coordinated preparatory process. Initially, the auto center specialists carried out diagnostics to identify the essence of the malfunction and find its cause. The data obtained are the basis for the development of a competent repair plan, which is subject to prompt and high-quality implementation.
In the process of repair, it is important to dismantle the gearbox. Sometimes the repair of the box of a UAZ PATRIOT IVECO car or another popular model comes down to replacing a worn out part and topping up transmission oil. That is why the dismantling of the manual transmission must be competent and extremely accurate.
The bulkhead of the manual transmission will allow you to determine the cause of the malfunction, so the importance of high-quality dismantling is difficult to overestimate. It is difficult to imagine the accurate removal of a manual transmission from a UAZ vehicle without the following set of tools:
⦁ Sets of socket or open-end wrenches and a wide range of sizes (from 10 to 36).
⦁Special wrench that will be used to work with flat nuts. For this occasion, amateurs often use bicycle keys.
⦁ Sets of flat and Phillips screwdrivers.
⦁ Pliers - service keys with curved or straight tips.
⦁Copper rod (rod for working with gears).
⦁A small piece of metal pipe to hold the nut when screwing each nut in a hard-to-reach place of the gearbox.
⦁Quality imported sealant, without which it is difficult to imagine a tight and reliable installation of gaskets, which will not allow the mechanisms to wear out prematurely.
All of the listed tools are a mandatory set of both a professional specialist and a novice master who will repair the gearbox or replace worn parts. Attention to the tools and the preparatory process in general will allow you to make repairs mechanical boxes a well-coordinated, high-quality and qualified procedure that will restore the car to its former safety, maneuverability and ease of control.
The procedure for dismantling UAZ 3151 gearboxes depends on:
⦁ car model - UAZ has three transmission options, each of which is characterized by its own design features;
⦁ reasons for the breakdown - if the breakdown is very serious, a specialist should quickly get rid of the broken gearbox for a qualified installation of a new gearbox;
⦁ preliminary diagnostics.
Dismantling gearboxes is considered the second stage, without which it is difficult to imagine a modern qualified repair of manual transmissions of all UAZ models.
Functional differences between the ADS and Dymos gearboxes
The multifunctional cross-country vehicle UAZ is equipped with a high-quality five-speed manual transmission, which has two main improved versions - ADS and Daimos.
The five-speed manual transmission is produced at the Ulyanovsk Automobile Plant to provide all basic models domestic SUVs. That is why the gearbox is characterized by a one-piece crankcase and synchronization in all forward gears. The first box appeared on the UAZ Patriot car, however, then the advantage of this production modification could be assessed by other models. So, use high-tech manual transmission owners of Simbir, Hunter and UAZ-3160 can.
Box ADS transmission characterized by the following features:
⦁Smooth functioning of mechanisms due to lengthening of the gear lever - with quiet or professional driving, the driver may not apply for a gearbox repair for at least 5 years.
⦁Presence of a bracket for fastening the return spring for quick and simplified fastening of the gearbox.
⦁Change general scheme Gearbox and Selective Device - Modifications have prevented oil leakage and ensured safe gearbox trim.
⦁Presence of a special sensor for uninterruptible power supply of the rear lights.
⦁Displacement of the filling hole by 2 cm - this minimal modification made it possible to improve the circulation of the oil-lubricant and prevent its leakage.
The manufacturer followed all the canons of modern high-quality manual transmissions, and at the same time tried to minimize the influence of negative factors on the mechanism as much as possible. Thanks to the standard structure, diagnostics and manual transmission bulkheads will become operational and easy procedures.
The Korean company Daimos offered its improved gearbox to Russian manufacturers in 2013. The main difference between the gearbox and the domestic version is the presence of electrical control, due to which drivers can completely abandon the use of the usual manual gearbox lever.
The Daimos gearbox is distinguished by the following technical characteristics:
⦁Using the built-in special washer instead of the usual manual shift lever. Thanks to this regulator, the control of the domestic SUV has become pleasant, comfortable, light and smooth.
⦁Changing the rear cardan shaft- lack of intermediate support and taming of the shaft.
⦁ The presence of a one-piece cardan of the rear axle.
⦁Lack of an intermediate bearing, since the cardan of the rear axle has become a one-piece mechanism that dispenses with gaskets.
The UAZ PATRIOT IVECO car has a mechanical five-speed three-shaft gearbox from the Korean company Dymos, which contributes to accurate and safe movement of the car and full control over it, even on an icy road or off-road.
This gearbox can be considered a modern and high-tech equipment that is not subject to rapid wear, even with an aggressive off-road driving style. Korean manufacturers remain true to their style - they are always ready to offer reliable mechanisms to motorists.
Transfer case UAZ gears are characterized by a two-stage mechanism, which is complemented by an aluminum casing. This mechanism is based on a chain drive for transmitting torque to the front axle.
The modified UAZ razdatka differs in the following changes:
⦁Stunning endurance due to the absence of the usual gear lever.
⦁Reduction of body vibrations due to the absence of an intermediate bearing in the rear axle universal joint ( this mechanism became solid).
⦁The design of the new transfer case is based on a chain drive.
⦁Lack of a handbrake brake - the additional braking device is now located on the rear wheels, like most modern models of off-road and endurance cars.
The transfer case of UAZ is a modern and modified set of mechanisms, which made it possible to achieve maneuverability and smooth movement of the car even by an inexperienced driver. Due to technical improvements, the distributor made it possible to prevent oil leaks, vibrations or knocks, excessive wear due to strong shock loads.
Gearboxes for UAZ vehicles are produced by both Korean and Russian manufacturers. Both options are modern, reliable and quality. However, they differ significantly in technical content. Repair of manual transmissions from two manufacturers is a process of prompt replacement of worn out mechanisms and oil refilling.
The DYMOS gearbox can undoubtedly be called an attempt to create a high-quality and reliable gearbox, which is located at the junction of a manual and an automatic gearbox. While the ADS gearbox aims to keep the original technical characteristics boxes of the UAZ HUNTER (and other model) and making it more comfortable, smooth and easy to control.
Technical features of the UAZ BUKHANKA gearbox
UAZ BUKHANKA is considered an all-wheel drive utility vehicle, which appeared on the domestic automotive market back in 1965. For half a century of history this car became multifunctional and versatile - it was used to transport goods, meet the needs of the army and deliver patients to hospitals.
The UAZ BUKHANKA gearbox performs a fundamental and responsible task - it monitors the variability indicators of the magnitude of the motor torque and transfers them from the engines to the driving wheels.
The four-speed gearbox of the UAZ-452 and other models is characterized by the following features:
⦁the presence of inertial synchronizers for engaging and shifting gears without extraneous noise or rumble - synchronizers help to equalize the speed of the teeth, which are connected before engaging;
⦁ one-piece cast-iron crankcase, which is the place of installation of the primary, secondary and intermediate shafts;
⦁ with helical gears of the intermediate shaft drive;
⦁ the presence of two plungers as a locking mechanism against accidental or deliberate engagement of several gears at the same time;
⦁four modes of forward motion with the following transfer values: 4.12; 2.64; 1.58; 1.00.
Despite the fact that the manual gearbox is prepared for high loads, it cannot do without scheduled and qualified repairs. The need for repair is usually the result of such negative factors:
⦁Using the car in extreme modes - UAZ 469 does not tolerate constant aggressive driving and operation only off-road or in icy conditions.
⦁Operation of a car with a faulty clutch - ignoring this breakdown may cause an emergency.
⦁Using low-quality oils for the drive axle - experienced auto center specialists advise car owners to follow the manufacturer's recommendations so that the car remains in service as long as possible.
⦁ Unprofessional or untimely maintenance - despite the fact that the UAZ is a hardy car, its repair should not be trusted by the hands of non-professionals. So, the sale of a gearbox allows you to solve half of the problem - the correct installation of the gearbox is important.
If the use of the gear cover is accompanied by extraneous noises or rattles, the car owner should send his car for diagnostics and carry out a prompt repair of the gearbox. If the diagnostics did not reveal serious breakdowns, the cause of the unpleasant grinding may lie in worn bearings and gears. Prompt replacement of these parts will again make gear shifting quiet and comfortable. To update the entire mechanism, auto centers often offer to buy a gearbox.
Worn synchronizers can “ask for replacement” when a motorist has to deal with tight or jerky gear changes. Synchronizer wear can be either planned or extraordinary. The second type of malfunction is usually caused by a critical decrease in the amount of oil in the crankcase.
Leaky gaskets should be replaced using imported sealant - it is of higher quality, reliable and proven.
Repair of gearboxes should be a complex, well-coordinated and qualified process, which is based on thorough diagnostics, troubleshooting, building a competent repair plan, preparing parts and grinding mechanisms.
The smooth operation of gearboxes depends on the use of quality lubricants in sufficient quantities. A minimum amount of oil can cause increased wear on gears and synchronizers, which may require attention with jerky gear changes or arbitrary activation of neutral mode.
Advantages and features of the UAZ FERMER checkpoint
UAZ FERMER is considered a cargo-passenger all-wheel drive vehicle, which is characterized by comfort, versatility and increased cross-country ability... Popularly, the UAZ-3909 model was nicknamed "FARMER", because in this car you can easily fit the driver, 7 passengers and plus 450 kg of cargo in an isolated cargo compartment.
Full cross-country ability, spaciousness and reliability make this car a versatile assistant in the field, fishing or hunting.
The presented model has a four-speed manual transmission, the mechanisms of which are distinguished by an amazing resistance to wear and tear. The first signs of abrasion of synchronizers and gears appear only after 70,000 km. At the same time, the repair of mechanical gearboxes is reduced to the replacement of worn parts.
The gearbox of this model is characterized by:
⦁Long stroke when first gear is engaged.
⦁Two plungers and a pin at the junction of 3rd and 4th gears to block the inclusion of two modes at the same time.
⦁Spring-loaded fuse to prevent accidental activation reverse.
⦁ Interchangeability - units and parts of various four-speed gearboxes are interchangeable.
Transmission malfunctions of this model are usually expressed in jerky gear changes, unauthorized transition to neutral mode or knocking of the gearbox. These malfunctions are provoked by irregular and poor-quality maintenance, lack of quality oil in the required dosage or abrasion mechanisms.
The driver's inattention to the abrasion of parts can cause premature wear of the entire gearbox. In this case, the driver will have to buy a gearbox and contact a service station to dismantle the old gearbox.
Specificity of the transfer case of modern UAZ modifications
The transfer case allows you to distribute the torque from the engine, therefore this mechanism is a mandatory unit for all-wheel drive vehicles, which include all UAZ modifications.
The Ulyanovsk Automobile Plant was the first to offer a helical transfer case for serial production to a UAZ SIMBIR vehicle. The peculiarity of this mechanism is the presence of helical gears for transmitting torque to the front axle of the car. The use of this technological modification allowed the manufacturer to get rid of the general noise level of the transfer case and make it more durable. In the low gear mode, the noise level remained at the same level, since the manufacturer left the spur gear drive gear for the low and direct gears.
Ulyanovsk plant introduced car enthusiasts to small-tonnage by truck UAZ-2360 (CARGO) in 2002. Taking into account the fact that this modification is based on the UAZ SIMBIR platform, its transfer case has a similar configuration.
The UAZ KARGO car is characterized by the following features of the transfer case:
⦁ replacement of ball bearings with roller bearings to significantly increase their carrying capacity;
⦁compatibility with engines, the torque of which is up to 30 kg × m;
⦁ reduction of the noise level to 8-10 dBa due to the use of helical gears;
Minimum maintenance - the transfer case only needs a timely change of the lubricant according to the operating instructions.
The gearshift mechanism on the UAZ PIKAP car, as well as on other trucks of the PATRIOT family and HUNTER models, remains single-lever - it provides for alternate engagement front axle and then neutral and crawler.
The transfer case of UAZ is mechanical and two-stage, it does not have center differential, but there is the possibility of disabling the front axle.
The helical razdatka is characterized by the following fundamental features:
⦁Rotation ratio of underdrive - 1:94.
⦁Centering on the outer race of the double-row bearing of the secondary shaft of the gearbox.
⦁Parking brake mechanism on the rear of the transfer case.
⦁Transferring torque to the drive shaft.
⦁When the front axle drive is engaged, the shafts are connected using a toothed coupling.
⦁Mounting the idler gear on the countershaft.
The use of the helical transfer case helped to minimize unpleasant noises, knocks and rattles during the operation of UAZ trucks.
Despite the fact that UAZ is a true pensioner of the domestic auto industry, the data four-wheel drive vehicles have a dozen models that differ in their design features and gearbox.
In UAZ cars, the gearbox can be either four-speed or five-speed. Despite a respectful list of features and specifications, these transmissions differ from each other by one indisputable fact: four-speed transmissions are interchangeable, despite the fact that they may differ in gear ratios. A five-speed gearbox should be bought very carefully - it cannot replace another modification.
The checkpoint needs routine diagnostics and timely repairs to keep the vehicle agile and safe. Screaming signs for repair can be considered:
⦁ Appearance of unpleasant knocking, grinding, vibration during gear shifting.
⦁Oil leaking.
⦁ Jammed gear lever in one mode or all.
⦁Jerk gear shifting.
⦁ Unauthorized switching to neutral mode.
The UAZ car itself is hardy - it is designed for high loads, off-road conditions, driving on an icy road and transporting bulky goods. However, this creation of the Ulyanovsk Automobile Plant, like most other cars, needs timely and high-quality maintenance, regular diagnostics and oil topping, use quality parts and lubricants, as well as in a relaxed or professional style of management.
A jerky gear change for no apparent reason provokes the mechanisms to work with a double shock load, due to which they are more quickly exposed to wear. Disassembling and troubleshooting the gearbox in a reliable and proven car service allows you to determine the cause of the malfunction.
Photo report of disassembly and repair of the gearbox of the UAZ HUNTER gearbox
The car came in for repairs due to the harsh noise from the manual transmission. As a result of disassembling the box, a defect in the bearing bearings on the gearbox shafts was revealed. We change bearings, gearbox oil seals. We wash the gearbox housing with nefras from inclusions of steel chips and old oil. Photos below:
The UAZ Patriot manual gearbox is designed to transmit torque and change the vehicle speed. An additional transfer case with a reduction gear is installed in the transmission design, which distributes the power flow between the drive axles. Depending on the year of manufacture of the car, a dispensing unit of domestic production or a unit developed by the Korean company Dymos is used.
The Patriot uses a 5-speed gearbox equipped with synchronizers for forward gears. The unit is connected to the engine using a clutch housing; a 1-disc dry friction clutch with hydraulic drive... The choice of speeds is carried out by a lever installed on the transmission case cover, the handle is brought out through a hole in the floor of the body into the passenger compartment. At the end of the lever there is a plastic tip with a speed selection diagram.
On machines assembled before 2005, there are 2 types of boxes:
- a unit assembled in Ulyanovsk (gear ratio of the overspeed 0.82);
- ArKPP unit developed by the Arzamas Machine-Building Plant (article 31606-1700010, gear ratio of the overdrive stage 0.86).
The Ulyanovsk boxes were used on the machines of the first batches, then the plant began to use the Arzamas unit, which was distinguished by an original step switching scheme. To engage the reverse gear, it is necessary to move the lever to the position opposite the 1st forward speed, and the 4th gear for forward movement is moved to the place of the standard location of the reverse speed.
Such an arrangement provides accelerated switching of the direction of travel when overcoming off-road by the swing method. The safety lock has been removed from the reverse speed engagement circuit, which reduces the time to select the direction of travel. The transmission was not distinguished by high reliability and precision of work, which is why, since 2005, it was supplanted by the Korean checkpoint Daimos.
A brief sequence of disassembly of the ARKPP unit from the UAZ Patriot:
- Dismantle the box from the car, and then rinse or wipe the crankcase from dust and oil drips.
- Remove the gear selection mechanism from the side of the housing, and then unscrew the plug with the overdrive spring lock.
- Remove the rings retaining the secondary shaft rear bearing from the seat. Remove the 5th speed crankcase mounting bolts to remove the axle support.
- Remove the left-hand threaded bolt holding the rear intermediate shaft support, and then remove the overdrive gear along with the needle bearing.
- Unscrew the overspeed fork fixing screw to remove the drive rod and clutch.
- Using a puller, remove the secondary shaft bearing together with the driven gear of the 5th stage. The puller is also used to remove the overspeed synchronizer hub from the intermediate axle.
- Remove the front cover and remove the circlip holding the bearing input shaft.
- Remove the intermediate shaft bearing caps, then pull out the axle and remove the reverse gear. To dismantle the gear, a bolt is used, inserted into a threaded hole drilled in the end plane of the shaft.
- Using a screw puller, pull off the bearings installed on the input and intermediate shafts.
- Slide the intermediate shaft forward to remove the front rolling bearing.
- Remove the input and output shafts assembly from the gearbox housing. Then remove the circlip to allow the intermediate axle to be removed.
Used since 2005, the Dymos transmission is equipped with 3 gear shafts, some of which slide along the splines to provide gear shifting. In the lower part of the body there is an oil bath, the lubricant is supplied to the rubbing parts due to rotation gear wheels scattering liquid over the crankcase. The box has an increasing 5th speed with gear ratio 0.88 to reduce engine speed and fuel consumption when driving on the highway.
The box is distinguished by the use of the classic step selection scheme. Disconnect the fuse to engage reverse gear. The unit has an increased clarity of switching, but does not tolerate loads poorly (for example, when driving for a long time in difficult off-road conditions). An additional advantage of the gearbox is the reduced noise during operation, the improvement is achieved due to additional mechanical processing tooth surfaces.
The disadvantages of the unit include the destruction during operation of the rear oil seal, due to which the tightness of the crankcase is disrupted. Transmission oil begins to go into the cavity of the distributing gearbox. Gears and rolling bearings in the main box, working in conditions of lack of lubrication, begin to wear out. The resulting metal dust gets onto the contact surfaces, accelerating the wear of the elements.
Damaged parts begin to make noise during operation, there are problems with the inclusion of steps, possibly spontaneous disengagement of gears.
Reasons for breakdown of the transfer case
The main reasons for the breakdown of the gear transfer case on the Patriot:
- Normal wear and tear of parts, leading to destruction of gears or bearings. To restore normal operating conditions, it is necessary to remove the unit and check the condition of the parts, damaged components must be replaced. When installing gears, parts should be selected according to the gap, which allows to reduce the noise of work.
- The use of tires of different diameters on the machine on the front and rear axles leads to difficult step switching. The cause of the defect may be damage to the gears, jamming of the spline connection or parts of the gear selection mechanism.
- Worn gears and bearings lead to spontaneous shutdown of speeds. The defect occurs due to breakdowns of the retainer of the selected gear or when the parts of the shift mechanism are bent.
- Worn gaskets or mechanical damage to the crankcase or covers lead to grease leakage from the housing. Oil can ooze through the rubber shaft seals, which eventually lose their elasticity and dry out.
Dymos transfer gearboxes use a chain drive and electric shift drive. With prolonged movement with increased load, the chain stretches and collapses, which leads to the appearance of extraneous noise. In the event of a problem with electronic components, an error notification is displayed on the display in the instrument cluster.
To clarify the reason for the appearance of the message, computer diagnostics are carried out.
During operation, the box does not require adjustment, but the driver must periodically check the oil level in the crankcase. Do not operate the unit if foam or water is found in the lubricating fluid. Contaminated oil is drained through a standard hole, and then fresh grease is poured into the crankcase (in accordance with the manufacturer's requirements). If oil leaks are found, it is necessary to disassemble the unit with replacement of gaskets or damaged covers or mounting screws.
Difficulty turning on the speeds indicates wear of the synchronizers or damage to the shift forks. Spontaneous knocking out of speed during movement occurs due to a broken clutch or due to wear on bearings or gears. To reduce the effect of wear products, it is necessary to carry out a routine oil change every 60 thousand km.
The drained fluid is checked for metal impurities entering the lubricant as a result of the destruction of gearbox parts.
To remove the Dymos unit with your own hands, you will need to follow the steps:
- Drain the oil from the crankcases of the main box and the transfer gearbox, and then disconnect the flange connection of the propeller shaft of the front axle drive.
- Remove the bolts securing the intermediate support for the rear propeller shaft. The drives are not disconnected from the axles, the pipes are retracted to the side of the box and are attached with a wire to the frame or suspension elements.
- Disconnect the speed sensor plug and then remove the catalytic converter together with the protective shield.
- After dismantling the clutch drive and intermediate drive parking brake it is necessary to remove the front exhaust pipe mount. Then a jack with a board is placed under the engine crankcase, which allows you to remove rear mount boxes.
- Remove the cross member located under the box. Then the unit should be lowered down, which makes it possible to separate the control levers of the main box and the transfer gearbox.
- Remove the reverse gear indicator plug and then remove the bolts connecting the box to the crankcase. The transmission assembly must be pulled back and moved down.
Dymos box disassembly algorithm
The transfer gearbox is attached to the gearbox housing with 2 nuts and 2 bolts. Then the gear selection mechanism is removed, which is additionally fixed on the sealant. There is a bolt inside the niche that can be unscrewed with a spanner wrench. To remove the rear cover, you need to unscrew the screws located around the perimeter of the crankcase. On the side of the box there is a bolt that holds the intermediate shaft with the reverse gear, which must be unscrewed. The second shaft securing bolt is partially unscrewed.
There is a plug on the left side of the box crankcase, under which there is a spring with a ball. After removing the plug, it is necessary to unscrew the screws securing the input shaft journal (located on the side of the clutch mechanism installation site). Remove the retaining ring and pull out the ball bearing using a puller, which will divide the case crankcase into 2 halves. Then the previously loosened bolt of the reverse gear axle is unscrewed, which allows you to remove the part.
Using a thin screwdriver or awl, the pins are knocked out holding the shift rods in place. Hang the crankcase cover with gears by the output shaft, and then heat the bearing seat with a burner. After heating the local area of the body to 400 ° C, the metal crankcase is knocked off the supports. Then the shafts are disassembled one by one, which makes it possible to determine the degree of wear of the parts. After the installation of new elements, the assembly is carried out in the reverse order; during installation, the position of the parts is taken into account and the tightening torque is observed.
1. Remove the fork 5 of the clutch release bearing and the bearing
2. Remove the shift cover / lever assembly.
3. Remove the reversing lamp switch.
4. Remove the stem head pin using a fine barrel bit.
Remove the bolt 1 of the idler reverse gear axle on the gearbox housing.
5. Remove the flange bolts and magnetically remove the springs and plungers.
6. Remove the mounting bolts and remove the input shaft bearing cover.
7. Remove the bearing 1 of the input shaft, after removing the circlip 2.
8. Remove the front gearbox housing by unscrewing the mounting bolts (shown by arrows)
9. Remove the circlip 4 of the output shaft bearing, the circlip 1, the protective ring 2, and two retaining half rings 3
10. Remove the bolt 1 of the idler reverse gear axle on the rear gearbox housing and remove the axle.
11. Using a fine cylindrical end bit, press out the gear shift lock pins.
Remove the gear shift rods.
Attention! Do not reuse the locking pins.
12. To remove the output shaft assembly, intermediate shaft assembly and rods from the rear case of the gearbox, heat the rear wall of the crankcase in the area of the double bearing using an electric heater.
Note:
For ease of dismantling, secure the output shaft, intermediate shaft and gear shift shaft with a rope or strap and hang;
Warm up the rear wall of the crankcase at a temperature of 400 ° C for about 4 minutes.
Attention! To avoid damage to the bearing, do not use a press or hammer to remove it.
13. After heating, dismantle the shafts by lightly hitting the rear casing with a rubber hammer.
Naturally, it does not pretend to be true, but it can be used as a visual guide to the repair of the Daimos gearbox.
So the checkpoint at the workbench. Where to begin? Now, I would start by screwing this gearbox back on and would never contact it. Joke type. However, in every joke ...
All the same, we must start by studying the only manual for repairing daimos that exists at the moment: tynts (third-party resource).
After studying this crooked manual, and it is really crooked, you will begin to have a vague sensation that you cannot yet characterize in any way. Later, yes. But not now. Now everything is rosy ...
So.
We unscrew the cover of the gear shift shaft. Please note that all joints are lined with a sufficiently high-quality sealant, and the screws sit on the thread sealant. Therefore, the process of separating cramps from cramps is difficult in most cases.
Along the way we inspect rubber boot switch rod.
Then, with a spanner key for 24, unscrew the reverse gear engaging sensor.
Please note that it is sealed to the body with a copper washer. According to science, they are disposable and when the sensor is installed in place, the shayolbox changes to a new one. Otherwise, oil leakage is possible.
We return to the gearshift stem box. We unscrew this bolt that closes the technological hole. It is used to unstitch the stock.
To my shame, I must admit that until that moment I did not have a normal set of drifts. And instead of drifts, I used old, unnecessary, not beautiful and for whatever reason, only I know, guilty drills, of a suitable size.
We also pay attention to the thread sealant and the copper washer.
Now, unscrew the three cover bolts from the wells of the speed switch rods retainer. There is also a thread sealant.
We stock up on a small magnet and use it to pull out the springs and locking balls. How Alternative option, rolls to turn the gearbox housing with the holes down and lightly tap ...
With the rear of the checkpoint, that's all for now. We pass to the bell.
We unscrew the front cover. I entrusted this business to the younger generation 😉
When the cover is unscrewed, it does not mean that it can be removed easily. Because the sealant glued it well enough. It is extremely convenient to pick up the edge of the cover with a long flat screwdriver, through the starter hole in the bell and use a lever to pry off the cover. Along the way, we evaluate the condition of the oil seal in the cover.
Now a small Kama Sutra with the removal of the retaining rings. I don’t know how to whom, but they were given to me in a very dreary manner ... And this is in the presence of a normal tool for removing them ...
In general, after the retaining ring is removed from the input shaft in the area of the front support bearing, the manual reads this phrase: "Remove the bearing from the shaft."
This is the first place where the breaking of the namba wan pattern begins. For the bearing:
- flush and stsuko flush
- closed type
- sits not just tight, but VERY tight ...
In general, in fact, you do not need to perform the "Remove the bearing" step at this stage. Take my word for it. Although ... If you have a tendency towards masochism, then by all means try. I guarantee the result!
I came to the conclusion that it is necessary to halve the gearbox housings without removing the bearing.
We unscrew dofig of bolts around the perimeter of the joint. Please note that there is one more screw in the gearshift stem box, above the stem!
I must also say that the halves sit very tightly on the guide bushings. There are only two of them, but you still won't be able to easily separate the halves. Plus, there's a strong sealant in there, be it wrong. In general, when you have a gap, we carefully increase it with improvised means until you rest against it. And you will resist! The gap will be about a centimeter and a half in size.
From this moment on, breaking the namba tu pattern.
The bottom line is that the front thrust bearing sits VERY firmly on the input shaft. And, of course, it interferes with halving the gearbox housing.
The essence of the process is clear from the photo. We post as much as possible in our own conditions. Take a piece of soft material such as copper / lumin / duralumin. This piece will be a spacer between the end of the input shaft and the popularly loved universal wrench, "Earth-to-Earth" class, "Sledgehammer" type ...
We put a soft gasket on the end of the input shaft. With the help of the mantra “How great is my love for Ipany Chinese engineers”, the memories of a certain mother and the reciprocating movements of a special key “Sledgehammer” type, we separate the bell with a support bearing from the input shaft.
It is after this stage that the bearing can be easily removed by hand from the seat in the bell, which will be on the floor 😉
Back to the fillet ...
To remove the rear gearbox housing, it is necessary to remove the pusher rod of the gearshift switches. For this, it must be pinned. Attention! There are two short pins, not one long one like on the shift forks.
Remove the second reverse gear axle bolt.
And remove the retaining rings from the output shaft end. Pull out the retaining crescents and remove the retaining ring from the secondary shaft tandem support bearing.
At this point, you will be awaited by a break in the template number sri ...
Because the manual says that it is necessary to unpin the gearshift forks and shift pushers. How this is supposed to be done when a good half of the pins are in the depths of the crankcase is not clear. But, if we remember that Chinese electricity has not yet been studied at all, then it’s even scary to think about Chinese mechanics ... Qigong there, Shao-lin and all that ...
In general, we tie all the giblets as they are and hang them again. We try to adjust the suspension so that the belts do not press on the 3-4 gear shift clutch and the axis of the shafts is maximally perpendicular to the plane of the mother earth. If you slide the clutch more than usual, an amazing adventure is guaranteed to find the three ejected synchronizer balls. Again, for masochists, the next stage in delivering themselves unforgettable pleasure ...
Then we need to heat the crankcase housing around the double bearing. I used an industrial hair dryer for this. The temperature is 500 degrees, within five to ten minutes. So that the crankcase would warm up thoroughly. Then, by reciprocating movements of a rubber mallet of the class "Narcosis", we present the crankcase body. The duration of the execution does not depend on anything and is purely random. Checked for three times assembly / disassembly of the unit (later I will tell you why) ...
Attention! In the case of the gearbox housing in the area of the partitions of the wells of the rods, there are two plungers. Do not lose them when turning the crankcase body over. Then you will not find such!
If your synchron balls have not ejected, you are lucky. At this stage, you can pour yourself 100 grams of good cognac and postpone further work for "Morning, evenings are wiser" ...
Take my word for it 😉
UPD1:
My dear readers!
Do not ask me questions about the repair of your gearbox, please! Firstly, I cannot and have no right to give advice without seeing the unit with my own eyes and without holding it with my own hands. Secondly, this is roughly how to make a diagnosis over the phone. No tests ...
This blog post is for informational purposes only. Its purpose is to show you visually the giblets and general methods work with this checkpoint. No more.
Today we are raising a necessary and difficult topic - the disassembly of the checkpoint. Each of us knows that disassembling a checkpoint is another task that requires a serious approach, time and a track method of disassembly. UAZ is equipped with a 5-speed manual gearbox of Korean origin Daimos... The unit is, in principle, reliable and often does not require intervention from the car owner for a very long time. But if the gears are switched with effort and spontaneously knocked out, then you still have to disassemble the box. The laboriousness of the gearbox disassembly process is a serious argument for a thorough diagnosis. before deciding on disassembly. We recommend putting special emphasis on the clutch since its functioning is directly related to the normal operation of the Dymos UAZ Patriot gearbox. But do not forget about the UAZ Patroit driveshaft, the elements of which are produced and affect the power load of the same box.
What you need to check first so as not to disassemble the Daimos checkpoint on the UAZ Patriot in vain:
- Oil level
- Fasteners on the bolted joints of the box itself
- Clutch Actuator Condition
- To disassemble the box first you need to dismantle it... First of all, the gearbox protection cover is removed.
- As for the cream of butter, opinions are divided here, some manage to remove the gearbox along with the oil, draining only from the distributor, while others are completely drained. If you disassemble the dymos uaz patriot gearbox completely, then you need to drain the entire volume of oil.
- It is necessary to dismantle the bearing fork and the bearing itself.
- Remove the cover of the shift mechanism together with the lever.
- Use a wrench to unscrew the reverse light sensor.
- Carefully knock out the stem head pin with a hammer.
- Unscrew the bolt, which functions as the idler reverse gear axle.
- When you have mastered all the flange connections, you can magnetically fish out the plungers and springs.
- Now we dismantle the circlip and finally remove the bearing from the input shaft.
- The front case of the Daimos UAZ Patriot gearbox is removed from the bolted connections.
- To get to the secondary shaft without losing important components, do not forget to remove the retaining rings from the shaft.
- To dismantle the axle, you need to unscrew the idler gear bolt.
- It is convenient to knock out locking pins with a thin punch, as neat as possible, but they still have to be replaced with new ones in the process of reversing the assembly.
- We remove the gear shift rods of the Dymos UAZ Patriot gearbox.
- The procedure for separating the crankcase and output shaft will require suspension by the shaft... This will open access to the crankcase. To remove the crankcase, you need to warm up its rear wall. Classic gas burners are increasingly replacing UV lamps with a power of 5-6 kW, because they are safer and have uniform heating without an open flame. After warming up, the shafts are disconnected by a hammer breakdown.
So, you disassembled the box, now we are carefully studying the condition of the gears and inspecting each component, checking for integrity. Dismantling the Daimos UAZ Patriot gearbox is a real, but not such an easy task, it can be seen even by the disassembly algorithm itself. So if you are not confident in your abilities, it is better to drive Patrick away in service center and entrust in the hands of professionals... Indeed, after disassembly, you will first have to rinse everything in kerosene or diesel fuel, so that clogging does not interfere with the normal operation of the unit, and only then put the "puzzles" of the checkpoint in the reverse order.
