Do-it-yourself repair of a VAZ 2107 five-mortar gearbox: disassembly, 10 photos, video

The design of the gearbox of classic domestic cars suffers from low reliability and inability to withstand high loads. Repairing a VAZ 2107 5-speed gearbox is a rather complex procedure that requires a responsible approach and extensive experience. However, if you know the procedure and are technically trained, you can perform the maintenance yourself. As a rule, cars begin to have problems with the inclusion/deceleration of speeds and the loosening of the rocker. With such symptoms, surgical intervention in the structure will be required.

Signs and causes of box malfunctions

Among the most popular reasons for visiting a service station are:

the appearance of specific noise while driving;
extraneous sounds during acceleration;
one or more gears do not engage, it is knocked out.

The symptoms are a clear sign of wear on the gears and synchronizers. Mechanics are often cited as the cause of the breakdown.

Overly aggressive driving. Stock transmissions are not designed for such driving conditions. Acceleration before the cutoff, too high a pace of movement on dirt or low-quality asphalt roads.
Natural wear and tear. Some cars are equipped with a frankly weak transmission. Such devices rarely survive the 200,000 kilometer mark.
Mechanical damage. Impacts against stones and curbs can damage the crankcase of the device, which causes lubricant leaks and dry operation.
Using low-quality oil or neglecting to service the device. If you pour a surrogate lubricant into the gearbox, the reaction can be unpredictable. Similarly, the mechanism responds to the lack of replacement of the working fluid.

Types of gearboxes in a car

Let's look at the distinctive features of each type.

A manual transmission, or, in other words, manual, is a classic type of gearbox. However, it has proven itself to be excellent among car owners who prefer maximum control over the car.
Automatic transmission has also been known since relatively ancient times. The gears in this gearbox change automatically, but driver intervention is still required to change direction. The disadvantage of automatic transmission is higher fuel consumption and slow acceleration compared to manual transmission. Although in new automatic transmission models the acceleration is improved.
The robotic gearbox is a manual gearbox with integrated automatic control. This variety combines the capabilities of an automatic (no need to monitor engine speed) and manual (for those who like fast acceleration).

The robotic (variable) gearbox has a significant drawback - the possibility of full use only on small cars. However, there are cases when a CVT was installed on crossovers such as the 2022 Honda CR-V with a 2.4-liter engine. The variable transmission design allows you to change the gear ratio thanks to continuously variable gear shifting or through electronic control. By changing the diameters of the pulleys, the speed of the car increases or decreases.

When and how often should you check your gearbox?

The manufacturer does not set a strict time frame for repairing the device. The only recommendation is a scheduled oil change.

The company recommends changing the fluid after 2,000 kilometers for the first time and after 60,000 kilometers for the second time. Further maintenance is limited to maintenance every 20,000-30,000.

CHARACTERISTICS

The car was produced from 1982 to 2013. VAZ 2107 configurations include small volume and power engines, from 1.3 to 1.7 liters. The minimum number of horsepower is 64, the maximum is 135.

All variations without exception are equipped with a five-speed manual transmission. Acceleration time to 100 kilometers per hour varies from 13 to 17 seconds, depending on the internal combustion engine. Although the maximum permissible speed of a car is 180 kilometers per hour, even the engineers themselves do not recommend exceeding the mark of 140. The danger is due to the lowest rating according to automotive safety standards (poor engine location, fragile body materials, etc.), a high probability of skidding due to low weight - 1040 kilograms - and rear-wheel drive.

Even the average fuel consumption - 9-10 liters - cannot be called an advantage of the car, since much more serious analogues with 3 or even more liter units consume comparable amounts of gasoline. By the way, there are no diesel versions of the VAZ 2107.

Box faults

There are several types of symptoms of breakdown or wear of the VAZ 2107 gearbox.

Lack of response to the inclusion of a position.
The speed takes off at full speed.
Increased noise, howling or grinding coming from inside the mechanism.
The gears are stuck in tightly.
Oil leaked.

The transmission does not start

The reason for the lack of an adequate response to the driver’s manipulations is:

wear of gears and gears;
abrasion of synchronizer bushings;
mechanical damage to the guide bushings;
synchronizer spring wear.

Knocks out gear when driving

The next trouble is the gearshift lever clicking out immediately after engaging the gear.

The reasons are:

the lever joint is jammed;
physical breakdown of the direct lever - the part is changed;
the shift forks in the gearbox are bent;
The clutch is not working properly.

Crunching and grinding in the box while driving

The following breakdown is caused by the following factors:

wear of bearings on shafts;
gear splines are worn out, parts are replaced;

There is not enough oil in the crankcase of the device, it is recommended to add lubricant.

Increased noise

The consequence of the following problems is increased noise emission.

Lack of lubrication in the gearbox housing. The mechanism runs dry, which provokes the appearance of extraneous sounds.
The fluid hasn't been changed for too long. After the lubricant wears out, a large amount of thick ointment consisting of soot, acids, and metal shavings forms inside the mechanism. The mass clogs the channels and oil starvation occurs.
Wear of gear teeth and bearings.

Difficult gear shifting

In this case, you will need to check the clutch - the device may not work correctly. Damage to the basket or disk is also relevant. Separately, the cause may be pouring an excessively thick lubricant or a malfunction of the synchronizer.

Oil leak

Lubricant leakage can be caused by factors.

Mechanical damage to the crankcase when it hits or hits another surface.
Wear of oil seals and seals caused by natural aging of rubber.
Overflow of liquid and, as a result, its displacement from the mechanism.

Gearbox VAZ 2107: what is it

What is a gearbox in a car design? The abbreviation “KPP” stands for “gearbox”. This is the name of the unit, which is designed to change the frequency of torque.

It is curious that the first gearboxes were invented not for cars, but for machine tools to change the speed of rotation of the equipment.

The purpose of the gearbox is to perform the function of converting the amount of torque that comes from the engine and transferring this energy to the transmission. This is the only way to change speeds in increasing increments.

The gearbox on the VAZ 2107 appeared in 1982 along with a new model in the AvtoVAZ line - the “seven”. Structurally and practically, this gearbox is still considered the most advanced unit among classic manual gearboxes.

For the first time, five-speed gearboxes began to be installed on the VAZ 2107

Gearbox device

The VAZ 2107 is equipped with a five-speed gearbox, that is, changes in the torque frequency are possible in five positions. At the same time, five gears allow you to drive forward at different speeds, and the sixth is considered reverse and is activated at the moment when the driver needs to reverse.

The shift pattern for these gears is no different from the classic four-speed one that was installed on earlier VAZ models. The driver just needs to depress the clutch pedal and move the gearshift lever to the desired position.

The external design of the box does not allow us to understand the internal design of the elements

It should be noted that, structurally, the box on the “seven” is a rather complex device, so the diagnosis and repair of this device is usually trusted only to professionals. However, the “seven” gearbox adopted the main parameters from the “five” one, since AvtoVAZ designers took the VAZ 2105 as the basis for the new gearbox.

Table: gear ratio ratios for VAZ 2105 and VAZ 2107

Model	VAZ 2105	VAZ 2107
Main couple	4.3	4.1 / 3.9
1st gear	3.667	3.667
2nd	2.100	2.100
3rd	1.361	1.361
4th	1.000	1.000
5th	0.801	0.820
Rear	3.530	3.530

Speaking about the general design of the gearbox on the VAZ 2107, it should be borne in mind that externally it has the shape of a closed housing. In this case, only three of its sides are completely closed (special durable covers are used for this), and the fourth side of the box “grows” into the gear shift knob. All lids fit tightly to the box, their joints are sealed.

The checkpoint consists of up to 40 elements

The main elements of gear shifting are “hidden” in the gearbox housing:

input shaft (four drive gears and synchronizers are installed on it);
secondary shaft (ten gears are mounted on its surface at once);
intermediate shaft.

Let's consider each element separately in order to understand at least the general principle of the design and operation of the gearbox.

Primary shaft

Just by the name you can understand that the input shaft is the fundamental element of the box. Structurally, the shaft is one piece with four gears and rotates together with them on a bearing. The rotating bearing itself is fixed in the lower part of the box and is sealed with an oil seal to ensure reliable connection.

All gears located on the shaft have different dimensions for ease of connection

More information about the VAZ 2107 input shaft: https://bumper.guru/klassicheskie-modeli-vaz/kpp/pervichnyiy-val-kpp-vaz-2107.html

Secondary shaft

We can say that the secondary shaft is, as it were, a logical continuation of the primary housing in space. It contains gears for 1st, 2nd and 3rd gears (that is, all odd numbers). All ten gears on this shaft have different dimensions, and therefore ensure the conversion of torque.

The secondary shaft, like the primary shaft, rotates on bearings.

The secondary shaft can be called the main element of the gearbox due to the increased loads that fall on its gears

Intermediate shaft

The main task of this element is to serve as a kind of “layer” between the primary and secondary shafts. It also has gears that are integral with the shaft, through which torque is transmitted from one shaft to another.

The main task of this element is to interface the work of the primary and secondary shafts

Set of forks

Ease of gear shifting while driving is provided by a set of forks. They are driven by the shift lever. The forks press on one or another gear of a certain shaft, causing the mechanism to work.

The fork is used to change the gears of the car.

Of course, there is a special hole in the housing through which lubricant is poured into the gearbox. This hole is located on the left side of the gear shift knob and is closed with a plug. The volume of the gearbox on a VAZ 2107 is approximately 1.6 liters of oil.

Diagnostics of box bearings

To check the condition of the gearbox bearings, the device must be disassembled and access to the parts must be opened. This method is the most accurate and effective.

After dismantling and disassembling the unit, you should check the shafts for play, the integrity of the seals and sealing rings. Additionally, the condition of the seats is checked. In normal condition, the formation of backlash and damage to rubber seals is unacceptable. If this is found, the part should be replaced.

Difficulty switching

The reasons for difficult gear shifting may be severe contamination of the lever linkage or jamming of the sliders.

In order to determine the cause of this malfunction, you need to take the shift lever housing and check if there is any jamming when the lever moves. If there is one, you need to establish the cause and eliminate it.

If the lever in the body moves without much effort, then the reason is in the sliders. After removing them from the gearbox housing, you need to carefully inspect them. Usually, in places where the sliders jam, marks remain in the form of abrasions and scratches.

Then you need to inspect the seats of the slides for the presence of particles that cause jamming. Alternatively, there may be a slight bend in the slider itself. In this case, the slider is replaced.

Rules for disassembling and assembling the gearbox

If the user has never encountered the repair of such a complex unit, the procedure should be carefully prepared.

Disassembly of the mechanism is carried out only after it has been completely cleaned of dirt.
All the tools required for disassembly are pre-prepared - keys, squeezes, pliers, lock ring pullers. It is also advisable to have a separate container for storing small bolts, nuts, and washers.
It is necessary to dismantle the mechanism parts by first treating the bolts with an anti-boiling agent.
When disassembling, the units are folded in the dismantling sequence.
Human memory is extremely unreliable - a photograph of a disassembled mechanism before its reassembly is the best reminder.
All gaskets without exception must be replaced. Recycling of seals is strictly prohibited.
No one has canceled the abundance of the cleaner. When washing the structure, you should not skimp on the cleaning material; the better you wash it, the more fun it will be.
Assembly of the unit is carried out exclusively in the reverse order.
If after installation there are excess parts left (which is not uncommon), the entire gearbox is completely rebuilt.

It is also necessary to maintain maximum cleanliness during work. Dust, metal shavings, or foreign objects can cause serious damage to the gears.

Front cover

It is installed in the clutch housing. Inside there is an oil seal for the input shaft. On the end wall there is a hole for draining transmission oil, which can flow out of the crankcase if the oil seal is worn. In addition, the box housing contains:

Primary and secondary shaft.
Gears, synchronizers.
Intermediate shaft with shift drive elements.

There is a filler hole in the left wall of the new VAZ-2107 gearbox. It is closed with a metal plug with a conical thread. At the bottom, the box housing is closed with a stamped steel cover. The crankcase is secured with ten nuts. There is a breather in its cavity. There is a passage for oil in the rear wall of the crankcase. it enters the cavity of the lid

Sources

https://7vaz.ru/remont/kpp-na-vaz-2107.html
https://rus-avtomir.ru/remont/kpp-vaz-2107
https://prometey96.ru/tyuning/korobka-vaz-2107.html
https://kalina-2.ru/remont-vaz/razborka-sborka-kpp-vaz-2107-5-stupka
https://iga-motor.ru/avtomobili/kak-raspolovinit-korobku.html
https://GrandFart.ru/tormoza/korobka-pyatistupka.html
https://AvtoSotka.ru/korobka-peredach/sborka-kpp-vaz-2107.html
https://CoptersWorld.ru/pro-dvigatel/transmissiya-vaz-2107.html

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Reasons for the bulkhead

The above procedure involves complete disassembly of the unit as a preventative measure. However, it happens that the manual transmission unit knocks out or slips during driver manipulations. Moreover, the VAZ five-speed transmission suffers from such things all the time. The reason for the repair may be one of the following factors:

the rocker lever gets stuck;
extraneous noise when driving;
one of the gears falls out;
Positions are difficult to switch on.

For a more accurate understanding of the process, you can watch video master classes of the process from experienced specialists.

4th gear slips out

On a five-speed VAZ 2107 gearbox, fifth speed overshoot can provoke wear of the gear, synchronizer, and related parts.

During the repair, the 3/4 clutch, the damaged element and a complete set of seals that are subject to separation during disassembly are replaced.

Note! Some mechanics claim that in 40% of cases, replacing the driveshaft mount and clutch fork saves the day.

5th gear slips out

The five-speed gearbox of the “seven” periodically gives out vagaries to the user due to insufficient gear lubrication. It is recommended that in case of knockout or tight engagement of a position, completely change the synchronizers, gear, fork and bushings - this will ensure stable operation of the unit.

Note! Before purchasing spare parts, it is necessary to troubleshoot them. Some stores sell "crooked" parts.

Repair of gearshift lever (backstage)

If the gearbox linkage (handle) becomes loose, repairs can be carried out even without removing the unit from the car. However, some experts recommend using “garage” repair parts. For the convenience of the reader and a clearer explanation of the process, it is better to complete the description in pictures.

Dismantle the cover and remove the locking bar from the rocker bushing.

After release, the lever axis is removed; for convenience, you can push the insert with a screwdriver or a pusher.

Usually the bushing itself wears out; you can replace it with a new insert or a standard M10 bolt.

Next, fasten everything in the reverse order and tighten the structure.

Dismantling the old-style gearbox

Before repairing an old-type VAZ gearbox, it is advisable to study the user manual or technical documentation. The main nuance is the absence of 5th gear - the classic system has only 4 positions. Therefore, the reverse gear is located separately. This should be taken into account during repairs.

Main technical characteristics of the VAZ 2107 box

The “seven” gearbox works in conjunction with the clutch. The VAZ 2107 is equipped with a single-plate dry clutch, which has only one (central) pressure spring. This is quite enough for convenient control of vehicle speeds.

The gearbox is only mechanical, three-code, five-speed. The VAZ 2107 has synchronizers for each forward gear.

The device weighs quite a lot - 26.9 kg without oil.

Video: operating principle of a VAZ manual transmission

What kind of gearbox can be put on the “seven”

The VAZ 2107 will willingly work with both a four-speed and a five-speed gearbox, so only the driver decides which model to choose.

If we talk about domestic “VAZ” gearboxes, then initially the “seven” was equipped with a four-speed unit, so you can always buy and install this particular unit. The main advantage of such a box is its increased performance - the driver drives 200 - 300 thousand kilometers without ever investing in repairing the device. In addition, the four-speed gearbox is more suitable for low-power 1.3-liter engines or for drivers who often transport heavy loads by car, since the gearbox is initially designed for high traction.

Five-speed gearboxes allow you to reach higher speeds. Younger drivers like this, since at the start and when overtaking you can squeeze maximum power out of the car. However, over time, such boxes began to be made from low-quality materials, so switching is not always clear.

Foreign gearboxes can also be installed on the VAZ 2107. Boxes from Fiat are most suitable, since it was this car that became the prototype of domestic models. Some car enthusiasts install boxes from older versions of BMW, but the installation procedure can take a lot of time, since the car’s original design does not provide for non-standard units.

When changing the factory gearbox, you should keep in mind that the new gearbox may not fit the dimensions and mounts to the VAZ

Replacing bearings

It is impossible to repair the bearings - when they wear out, the non-separable structure changes entirely.

Main shaft bearing

For dismantling you will need:

clamp the input shaft into a yew;
Using a special puller, remove the bearing from its seat.

The removal procedure is accompanied by slight tapping of the part. The installation procedure is performed in reverse order.

Secondary shaft

The only difference between the procedures is the use of different sized bearings.

Intermediate shaft

The procedure is similar. Using yews and a special puller.

Five-speed manual transmission

The seventh model Zhiguli has a five-speed gearbox with five forward speeds and one reverse.

It is made of duralumin and has similar covers on the front and back. The clutch cover is attached to the front of the box using studs. A steel cover is installed on the bottom of the device. There are sealing gaskets between the box body and each lid.

The front cover is connected to the clutch housing using a press fit. There is a hole in it for the input shaft to exit and install the cuff.

Inside the box, shafts with gears, synchronizers and gear shifting devices are installed in a certain order. There is an oil filler hole on the right, and a drain hole with a magnetic plug on the bottom.

At the bottom left of the cover comes the speedometer cable, which is driven by the secondary shaft using a gear.

The gear shift lever is on top. Consists of a gear selection device, rods and a locking mechanism. A handle is attached to the lever on top. This entire structure is attached to the lid using three studs.

Type of gearbox:

Clutch cover.
Breather.
Box body.
Rear cover.
Gear shift lever.
Lever housing.
Coupling flange.
Screw.
Speedometer drive.
Tray cover.
Hole for filling.

Exploded parts:

Fork for engaging 3rd and 4th gears.
Fork for engaging 1st and 2nd gears.
Fork fastener.
Engraving washer.
Fork rod for engaging 1st and 2nd gears.
Rusk.
Fork rod for engaging 3rd and 4th gears.
Gear shift lever.
Fork rod for engaging 5th gear and reverse.
Rusk.
Rusk.
5th gear and reverse detent spring.
Retainer cover with gasket.
Retainer springs.
Ball retainers.
Fork for engaging 5th gear and reverse.
Sleeve.

Moving parts of the gearbox:

Intermediate shaft.
Front intermediate shaft bearing.
Rear main shaft bearing.
Input shaft with 4th gear gear.
Synchronizer clutch for 3rd and 4th gears.
Synchronizer clutch hub.
Synchronizer clutch for 1st and 2nd gears.
Synchronizer clutch hub.
Front secondary shaft bearing.
Secondary shaft.
Intermediate bearing of the secondary shaft.
Rear secondary shaft bearing.
5th gear synchronizer clutch.
Synchronizer clutch hub.
Reverse gear.
Gear with 5th gear synchronizer.
Speedometer drive gear.
Gear block for 5th gear and reverse gear.
Gear block bearing.
Reverse intermediate gear.
Reverse idler gear axis.
Rear intermediate shaft bearing.
Gear with 1st gear synchronizer.
Gear with 2nd gear synchronizer.
Gear with 3rd gear synchronizer.

Replacing oil seals

Structurally, the oil seal is a sealing device that closes the passage to oil. When a part wears out, the housing stops holding liquid and an oil leak occurs.

To dismantle the part, you will need to perform a certain sequence of actions.

The procedure is performed like this:

completely disassemble the gearbox to open access to the oil seal;
pry off the seal ring with an awl;
remove the oil seal itself from the shaft;
Installation of the new part is carried out in the reverse order.

Disassembling the secondary shaft oil seal is more difficult.

Remove the centering device from the shaft flange.
Use a special puller to pull the flange off the secondary shaft along with the washer;
Use a screwdriver to pry the oil seal out of its socket.
Carefully install the new seal.

Splines and forks

There is a reverse gear between the wall of the VAZ-2107 gearbox housing and the fifth gear. Since it produces a reverse movement, the part is not connected directly, but through an intermediate gear. It is installed on the axis of the rear wall of the transmission housing. The gear fork fits into the groove of the gear. When it moves, the intermediate element engages with the reverse gear. The secondary shaft has synchronization clutch hubs. They are motionless. A speed synchronization clutch is put on the gear ring of the hub.

As for the shift fork, it fits into the annular groove of the synchronization clutch. The latter moves along with the movement of the rod. The clutch begins to act on the synchronizer blocking ring and, as a result, moves it. Thanks to the friction force, the rotation speed of the hub and gear is equalized. The teeth mesh with the gear timing ring. Torque begins to flow to the secondary shaft through the hub and clutch from the gear.

How to replace gears and synchronizers

Initially, it is recommended that if replacement is necessary, contact a car service center. However, if you are confident in your abilities, you can perform the operation yourself. For this you will need:

yews;
special puller;
flat head screwdriver.

Next, the procedure is performed as follows.

Remove the shaft from the gearbox and clamp one side of it into a yew, having previously wrapped it with a soft lining.
Using a screwdriver or awl, remove the retaining rings and all bearings.
Then rest the shaft against the double support and remove the gears from it in direct sequence.

Transmission repair without removing the box

In case of emergency, you can repair the VAZ 5th transmission without removing the housing from the car. When performing the procedure, the car is driven onto an overpass or inspection hole. All manipulations are performed upside down, which complicates the process. Therefore, experienced auto mechanics prefer to first dismantle the unit from the car.

Gearbox oil for VAZ 2107

A special transmission oil is poured into the VAZ gearbox. It is necessary to lubricate gears, as it extends their service life.

The choice of gear oil depends on many parameters: the driver’s finances, manufacturer’s recommendations and the preferences of the owner of a particular brand. You can undoubtedly fill the gearbox of the “seven” with gear oil from the following companies:

UFALYUB UNITRANS 85W-90;
LUKOIL TM-5 85W-90;
SAMOIL 4404 80W-90 or 85W-90;
FAIR SUPER E-80W-90 or T-85W-90;
TNK TRANS GIPOID 85W-90 or 80W-90;
AGIP ROTRA MP 80W-90 or 80W-95;
NORSI TRANS 80W-90 or 85W-90;
NOVOIL SUPER T 80W-90;
SPECTROL FORWARD 80W-90;
MP GEAR LUBE-LS 80W-90 or 85W-140 (GL-5).

The brand is always popular not only among VAZ drivers, but also among foreign car owners

The volume of liquid poured is usually 1.5 - 1.6 liters. Filling is done through a special hole in the left side of the box body.

How to check the oil level in the gearbox

If you suspect an oil leak, you need to check the level in the box. To do this, you will have to put the VAZ 2107 on the inspection hole and start working:

Clean the drain plug and filler hole on the box body from dirt.
Take a 17mm wrench and use it to unscrew the filler plug.
Use any suitable object (you can even use a screwdriver) to check the oil level inside. The liquid should reach the bottom edge of the hole.
If the level is lower, you can add the required amount of oil through a syringe.

You can check the level with a screwdriver, a narrow ruler, a bolt or a special probe purchased in a store.

How to change the oil in a VAZ 2107 gearbox

To change the oil in your car, you will need to prepare in advance:

container for draining used liquid (at least 2 liters);
key to 17;
hexagon;
screwdriver;
rags.

It is recommended to replace it immediately after driving the car, as hot oil will drain out of the box faster. The replacement procedure is relevant every 50 - 60 thousand kilometers.

VAZ 2107 needs to change transmission oil approximately every 3–4 years of operation

Operating procedure

To prevent the work from causing trouble, it is best to immediately cover the space around the box with rags. Next, follow the following diagram:

Unscrew the oil fill plug on the box body.
Place the drain container under the plug and open it with a hex key.
Wait until the oil completely drains out of the box.
Clean the drain plug from old oil and install it in place.
Carefully pour 1.5 liters of fresh oil through the filler hole.
After 10 minutes, check the level, if necessary, add more lubricant and close the plug.

Photo gallery: do-it-yourself oil change in a box

It is better to clean the drain container under the plug in advance.

Old oil will leak out faster when the box is warm after driving.

It is better to pour the smear through a funnel

Lever tuning

The gear lever is located on the “seven” somewhat poorly, some believe that it is too long, others stretch far, and a general remark when turning on the reverse gear is added to the main ones, that we hit our hand on the passenger’s knee.

Some select levers from foreign cars that are suitable in size and secure them. The second, and easiest, thing to do when upgrading the handle yourself is to simply make it shorter. To do this, the lever rod is sawed off to 5 - 7 cm in length and the thread is re-cut.

The most radical way of tuning is to move the lever closer to the driver and reduce its travel when changing gears. It looks, when brought to its logical conclusion, solidly.

Read more about this procedure on the website.

The above “tuning of the lever makes the interior of your car unique, but do not forget about driving safety because the given examples have their pros and cons, and it’s up to you to decide whether to do them or not.