Replacing the Lada Kalina gearbox: why is it needed and how to replace it correctly

At which Kalina gearboxes can adjustments be made?

Lada Kalina cars are equipped with two types of manual gearboxes, which have different types of drive - lever and cable.

Adjusting the Lada Kalina gearbox lever

In the first case, the force of the lever, connected by a hinge to the transmission rod, is applied to the rod of the gearbox gear shift device. This design requires periodic adjustment of the Kalina gearbox linkage due to the gear selection lever moving beyond the range of movement provided by the design during operation. Most often, correction is required for the first generation Kalina gearbox with a mileage of more than 100 thousand km.

Unlike a traditional rocker, a cable shift drive effectively dampens the penetration of vibrations into the vehicle interior. The reduced lever travel in the longitudinal and transverse directions increases comfort when switching. Eliminating rigid traction eliminated the causes of incorrect operation when selecting gears, but problems can be caused by a malfunction and subsequent incorrect adjustment of the clutch on the cable box on the Lada Kalina-2. Insufficient oil level in the box can also be a reason for complaints about the quality of the device.

Adjustment of the gearbox on the Kalina with a cable drive is not required. Two cables with obvious signs of wear on the jackets or the appearance of effort when switching are removed and replaced. Avoiding sharp bends along the route is a necessary condition for trouble-free operation of flexible cables. After replacing the cables, additional adjustment of the clutch of the cable box on the VAZ Kalina-2 will be useful.

How to replace the release bearing on a Lada Kalina with your own hands

1. Signs of a faulty clutch release bearing on Kalina
2. Dismantling the gearbox and removing the release clutch
3. Installing a new release bearing
4. Replacing a bearing without removing the box
5. How to choose a “squeezer”: number, dimensions, price
6. Repair tips and useful videos

The release bearing (VP) is a ball bearing that is installed in a special clutch with a spring and moves along the input shaft bushing. The part is used to press the clutch disc and remove the flywheel from engagement with the gearbox. The release bearing (Kalina VAZ 1118, Priora, Granta), like the clutch, periodically fails after a long mileage or improper operation and maintenance. If a clutch malfunction occurs, the gearbox will need to be removed for repairs, but there is a method in which the Kalina release bearing is replaced without dismantling the gearbox. Many VAZ 1118 owners often ask the question “How much does it cost to replace a release bearing on a Kalina?”, we can say with confidence that in a car service this repair will cost about 3,000 rubles. Replacing it yourself according to these instructions will take you 3-4 hours, so the choice is yours.

Note: It is worth noting that without removing the box, repair time is reduced, but the process itself is not simplified.

The article outlines a guide to replacing the clutch release bearing on a Lada Kalina with removing the gearbox, and also shows a method without removing it. Additionally, information is provided on the selection of spare parts, numbers, prices, and sizes. The material is accompanied by numerous photographs, as well as supporting videos, including on replacing the clutch on Kalina. This instruction is suitable for owners of Lada Priora, Lada Granta, VAZ 2110-2115 cars.

Other reasons for the lack of reverse gear on the VAZ-1118

The gearbox may not yet turn on if the link (thrust) is not adjusted, but in this case problems will also arise when trying to turn on some other speed (for example, first or fifth). That is why, whenever removing a manual transmission, it is recommended to put marks on the slide so that during reassembly it can be installed in exactly the same position.

Another reason for the malfunction of the gearbox is an unadjusted or poor clutch, but here, too, other gears either do not engage or shift with a crunch. The travel of the clutch pedal on Kalina is adjusted by decreasing or increasing the length of the cable; when the disc is worn out, the car begins to drive with slipping and does not pick up speed well. One of the main signs of bad ferrodo is the smell of burnt linings, which is especially noticeable when the car picks up speed and operates under increased load. At the same time, the free play of the clutch pedal increases, and it is not always possible to adjust it.

The Kalina gearbox has its own characteristics that every car owner should know. The manufacturer installs 5-speed gearboxes on the cars, which have 1 rear gear and 5 forward gears. Some car owners complain that the gearbox makes a squeaking noise when the lever is shifted. The thing is that the manufacturer installed special synchronizers on all forward gears. They are the ones who create the creak. When adjusting or replacing synchronizers, the squeak disappears. To carry out repairs, you will need a diagram of the device.

Most often, buyers choose cars with manual transmissions at car dealerships. It must be said that their power directly depends on how many valves there are in the car’s engine. More recently, the car plant has carried out work to improve them; changes affected engines with 8 and 16 valves. The installation of reinforced parts made the engines more powerful and reliable.

Choice

ATTENTION!. There are two types of clutch installed on the Lada Kalina:

• 190 mm (three bolts at the starter),
• 200 mm (two bolts at the starter).

You can tell exactly which one you have after analysis. We recommend doing just that. But you can tell by the starter, or rather by its mounting.

We installed VALEO 828003 on our editorial Kalina. It cost about 3,500 rubles per set.

Articles

• LADA 21100-1601000-00
• Krafttech W05200G

If troubles arise on the road, it is recommended to have it towed or seek the services of a tow truck, since there is a risk of gearbox failure.

Replacing a manual transmission

If the circumstances were not the most favorable, and you still had to resort to replacing the Kalina gearbox, you need to know the correct sequence for dismantling the transmission.

Preparation

Before removing the gearbox, read the vehicle's operating instructions or watch a video about replacing the gearbox on a Kalina.

After this, prepare your work area. Replacing the gearbox on Kalina is carried out only when the car has cooled down. Raise the car on a lift or drive it into a pit. Don't forget about safety requirements. Ask a partner for help to carefully remove the gearbox.

Be sure to drain the transmission oil to prevent it from leaking when you remove it.

Tools

Prepare the necessary tools - wrenches and sockets of various sizes, a wheel wrench, a jack, an empty container.

Removing the box step by step

The first step is to unscrew the engine protection, which is secured with 6 bolts. The next step is to drain the oil from the gearbox - to do this, unscrew the filler and drain plugs of the gearbox.

1. Remove the battery for convenience and to avoid spontaneous short circuits. The battery platform will also be in the way, so unscrew the 4 bolts securing it.
2. Disconnect the throttle cable. To do this, remove the special bracket that secures it and pull out the cable.
3. Remove the air filter. After disconnecting the main pipe, pull out the filter housing towards you. Under it you can see the clutch cable, which is located next to the starter; unscrew it as well.
4. The next step is to unscrew and remove the starter, which also makes it difficult to get to the box. Now jack up the car and remove the front wheels.
5. After removing the wheels, unhook the left drive. Now you need to hang the engine on a hydraulic jack. Remove the right drive. Be sure to insert the differential lock plug to prevent the planetary gear from flying out. In the case of a cable box, loosen the fastenings slightly so that the cable drives can be disconnected from above.
6. Having unhooked the rocker arm from the box (by loosening the clamp), disconnect the torque rod. More precisely, you need to remove the part that is closer to the gearbox driveshaft.
7. Hang the box on a hydraulic foot or special support. A “cushion” is screwed next to the cardan - unscrew it from both the body and the transmission, it is secured with bolts from the end side. Then you can easily crawl to the right front drive, which needs to be removed.
8. To remove the box from the engine, unscrew the 4 bolts around its perimeter.
9. The box is free. All that remains is to carefully lower her to the ground, pulling her out from under the car. If dismantling is carried out in a pit, then ask your partner for help to remove the gearbox without dropping it.

Bolt for securing the Lada Kalina gearbox.
The gearbox can be replaced at a service station. The price for replacing a gearbox on Kalina starts at 5 thousand rubles.

Which box to choose

Replacing the Kalina gearbox involves installing a transmission that was installed on this model by the factory. Mechanical gearboxes are considered the most reliable.

They are easy to repair and maintain and do not require special skills from the car owner during repairs.

When switching from one system to another, significant modifications to the Lada Kalina are required. The price for a gearbox with rigid traction is about 15 thousand rubles. If you have a new Kalina model, and it has a cable-driven gearbox, you will have to pay 25 rubles for a new unit.

Installing the box step by step

The step-by-step installation process is similar to its dismantling, only in reverse order. With the help of a partner, install it in its place, connecting the splines of the gearbox input shaft and the engine crankshaft, connect all attachments and pipes. Pour transmission oil into the box. The replacement of the gearbox on the Lada Kalina is almost complete. Connect and adjust the rocker rod drive.

Installing a gearbox on a car

Start the car, let it warm up, inspect the engine compartment for leaks, try changing gears. The move should be soft and without extraneous sounds. If so, the box is installed correctly. Turn off the car.

After the car has cooled down, install the engine protection.

Choosing the best oil

When choosing oil for the gearbox, and for other units of the Lada Kalina, you must take only the original fluid. Since, recently, the market has a significant share of fakes, it is necessary to approach the issue carefully.

Thus, Kalinovody chooses to fill with TNK TRANS KP Super oil. As practice shows, the gearbox on it begins to operate more quietly, and the speed shifts smoothly. Monitor the oil level in the gearbox.

And in an 8-valve engine they prefer to pour what is recommended by the factory, just like in a 16-valve engine. A 16-valve engine is more capricious, so you need to be very strict when choosing oil.

A table of recommended oils for Kalina, as well as their coding, was found in the factory service manual.

It is worth remembering that only transmission oil is poured into the gearbox. After a major overhaul, at the time of break-in, you can use the simplest thing - TAD-17.

Consequences of untimely replacement

Since, over time, gearbox oil loses its properties, both physical and chemical, this can cause the following consequences:

• Wear of shafts and gears. This is due to the fact that after 150,000 km the oil loses its physical properties, namely its cooling effect. Thus, rotation of shafts and friction of gears leads to heating and increased wear.
• The loss of chemical properties will also lead to wear and accumulation of metal shavings in the oil, which will affect not only the gears, but also the bearings.

All these reasons can lead to increased wear, which will lead to premature overhaul of the gearbox.

On Lada Kalina 70w-90!

Replacement process (briefly)

Read more about changing the oil in the material: changing the oil in the gearbox on a Lada Kalina.

Changing the oil in a Lada Kalina gearbox is, on the one hand, simple, but on the other, not so easy. To do this, you will need tools, namely: a jack, flushing oil, a 17 mm wrench and a container for working off.

Now that everything is ready, let's begin the work process itself:

1. We place the car on a lift or pit.
2. Remove the air filter.
3. Using a dipstick, check the amount of oil.
4. We remove the lower engine protection.
5. Unscrew the drain plug on the gearbox.
6. Draining the oil can take up to 40 minutes.
7. We tighten the drain plug, while not forgetting to replace the O-ring.
8. Now, insert a watering can with an extended tube into the dipstick.
9. Fill in about 3 liters of oil.
10. We wipe the dipstick and insert it, and then remove it. We look at the level, it should be between the maximum and minimum indicators.

That's all, the oil in the box has been replaced. We drive 10-15 kilometers and look at the level indicator. If necessary, add oil.

When did they start installing the cable box?

In 2013, AvtoVAZ decided to abandon the 5-speed manual transmission with index 1118, which was installed only on the Lada Kalina since 2004, in favor of a newer transmission, also with 5 gears. Thus, the cable box on the Kalina received serial number 2181.

Why did they abandon the rocker box?

There are several reasons why the manufacturer abandoned the rocker box. Firstly, to reduce the vibrations that occur on the lever connected to the transmission through a rigid rod, as a result of which they switched to a cable gear shift drive. Secondly, when installing multi-cone synchronizers, the force applied to shift first and second gears also decreased. Thirdly, to make gear shifting easier, the bevel angle of the synchronizer teeth was reduced.

Gearbox slide

Next, in order to stop oil leaks, it was necessary to move the gear selection mechanism from bottom to top, which was done. A selector plate was also installed, which resulted in clearer gear shifting. Well, to prevent the driver from accidentally engaging reverse gear, an electric lock was installed instead of a mechanical one, as on the previous gearbox.

Due to the fact that the gearbox gears are not sufficiently processed and have a tolerance of 0.2 mm, many Kalin owners complain about the “howl” of the transmission.

Another reason for abandoning the 1118 manual transmission is unclear gear shifting, especially on a warm engine, which is why owners have to adjust the gear control drive. The process is certainly not complicated, and even “two schoolchildren” can cope with it, but it’s still not pleasant.

As with all other AvtoVAZ transmissions, transmission seals are also famous for their low reliability; due to the manufacturer’s savings on seal material, oil leaks from the box. Replacing oil seals is not an expensive procedure, but if you miss the moment, the lack of lubrication in the manual transmission can lead to serious consequences. Fortunately, to check the oil level in the gearbox there is a special dipstick, which is located near the battery.

Left drive oil seal

AvtoVAZ determines the service life of this manual transmission at 160-180 thousand kilometers until it is completely replaced. But in practice, for a comfortable ride, Kalin owners change or upgrade most of the transmission components already within the first 100 thousand mileage.

How is a cable gearbox better than a rocker gearbox and why?

Having taken into account all the negative reviews from Kalina owners about the rocker transmission, AvtoVAZ decided to install a cable box on Kalina since 2013. For the first time, they began installing a cable gearbox on Kalina, Granta, and Priora, which were equipped with 16-valve engines

For the first time, they began installing a cable transmission on the Kalina, Grant, and Priora, which were equipped with 16-valve engines.

As a result of replacing the rigid gearbox control drive with cables, some of the shortcomings associated with the rocker manual transmission were eliminated. In particular, the travel of the gear lever has been significantly reduced, and the gear shifts themselves have become clearer. The vibration on the gearshift lever has almost disappeared, but still not completely, and car owners also slightly modified this mechanism. This suggests that problems with the cable drive of the Lada Kalina gearbox were also present, but were not as noticeable as with the previous transmission.

AvtoVAZ recommends filling this manual transmission not with mineral oil, as was the case before, but with synthetic oil. Thanks to this, even at sub-zero air temperatures, the gears are switched on “cold” with ease, and there is no need to wait for the oil in the transmission to warm up, because synthetics retain their operating properties at a much greater minus, unlike mineral oil. Also, the volume of oil poured into the box has decreased, since the gearbox itself has become more compact.

Transmission oils recommended by AvtoVAZ

Experts recommend using oil with a viscosity of 70W80 to 80W85.

Manufacturers:

• Rosneft
• Shell
• Liqui Moly
• Lukoil
• Castrol
• Mobile

It is also worth mentioning that the ZIC company has also succeeded in the production of transmission fluids and is gaining a lot of positive reviews.

recommends using the following brands of oil:

• Lukoil TM4 with viscosity grade: 75W-80, 75W-85, 75W-90, 80W-85 and 80W-90
• NOVOIL TRANS KP with viscosity grade: 80W-85
• Rosneft KINETIC with viscosity grade: 80W-85
• TNK Trans KP with viscosity grade: 80W-85
• TNK Trans KP SUPER with viscosity class: 75W-90
• Trans KP-2 with viscosity class: 80W-85
• Shell Transaxle Oil 75W-90

The use of oil from TNK is justified in cases where the car has a low annual mileage (no more than 20 thousand kilometers).

Repair, features and technical specifications

Inside a VAZ 21118 car, like any other, there is always a gearbox. For a model such as Kalina 1118, this device is a mechanical type design, which is equipped with one reverse stage, as well as 5 forward stages.

Gearbox from Lada Kalina.

In Lada Kalina, the gearbox is structurally combined with a differential, the main gear. Transmission differential repair should also take this into account.

The mechanism body of the VAZ Kalina car is presented in the form of three aluminum copper crankcases:

• Back cover.
• Box.
• Clutch.

Special sealants are applied between them when assembling and repairing the gearbox.

Removal and installation of the gearbox

Servicing the gearbox assumes that the mechanism will have to be removed and its position changed. Before doing this, you need to install the vehicle itself on the lift. The ignition must be turned off completely and the parking brake must be used.

How to repair a gearbox? To do this, disconnect the minus terminal from the battery. The hood must be opened completely. Any manual on gearbox repairs writes about this.

The oil filler cap is also removed. It is necessary to install the previous item after the screen is removed. The gearbox requires loosening the clamp responsible for fixing it. The inlet pipe hose must be disconnected from the corresponding sensor. Gearbox lever play requires the same actions in practice. Then you need to unscrew the air intake nut.

Mechanical part

If the reverse gear on the Kalina does not engage, the reasons may be in the shift mechanism. The latter has a spring in its design. It breaks often. If the part “falls” to the bottom of the box, it will not interfere with gear shifting. The driver can drive like this for several years, not suspecting that a spring has fallen out of the mechanism.

But if it gets stuck in the grooves, reverse gear breakdowns will be inevitable. Depending on the position of the part, the speed may turn on periodically or not work at all. In this case, you will have to completely disassemble the gearbox and pull the stuck element out.

What tricks have they done with TsBKE?

Some time ago, the list of defects would have included the failure of the CBKE, that is, the body electronics unit. The firmware intended for the specified Grants/Kalina-2 unit has now been updated. As a result, we managed to get rid of the malfunction completely - the equipment itself cannot fail. But not everyone likes how the new firmware works - some owners experienced an incomprehensible defect when the reaction of the lamps to the actions of the warrior became “strange”. However, we have published a video where a corresponding example is given further, and you can evaluate the quality of the work of the Central Bank of the Russian Federation “live”.

In the “first Kalina”, by the way, electrical devices were controlled by individual elements (relays, toggle switches), each of which could theoretically fail, which would require its search and replacement. The design of "Kalina-2" is more modern, something is being updated in it, and the use of some components has to be abandoned. This was the case with the South Korean EUR. Now Russian amplifiers continue to be used.

Features of electrical equipment of Lada Kalina-2

Technical features of the gearbox

The drive gear block is engaged by the input shaft

This is important to consider when repairing a gearbox. As for the input shaft itself, a constant clutch is created for it with the front gear elements that perform similar functions

When repairing the secondary shaft, we must remember that it has a hollow structure. It is thanks to this that the oil reaches the driven gears without any problems.

The design of the gearbox is such that repairs cannot be done without the use of special circuits. In this case, the radial clearance on the roller bearings is no more than 0.07 millimeters.

Repairing the gearbox is also a rather complicated process. Especially considering that 0.04 millimeters should not exceed the same figure, but for ball analogues.

Location of the checkpoint backstage on the Lada Kalina.

The oil sump is responsible for supplying oil. It is located in the area of ​​the front bearing, fixed behind the output shaft. Major repairs often affect such details. If you select the desired thickness of the rings, it will be possible to adjust the tension indicator. The dimensions of the seals are easy to find in the instructions; these parts can be replaced without problems, even at home.

When repairing the gearshift knob, you must remember that the driven gear of the gearbox on this machine is attached to the differential flange. Through the saloon, the atmosphere is combined with the box itself, located at the top of the structure we are considering.

Lever repair is not the only operation that needs to be carried out from time to time. Sometimes it is necessary to replace bearings; this is done when extraneous noise appears. A gearbox repair kit must be purchased if excess noise becomes noticeable when pressing or releasing the clutch pedal.

All control drive elements of the Lada Kalina gearbox.

The repair manual says that the box is controlled using a drive, which consists of several elements:

• Switch rod.
• Spherical bearing.
• Lever arm.

According to the manual, cable structures are always equipped with jet traction, then the gears do not turn off on their own. One of the ends of the rod is connected to the lever, and the other to the motor. If the seals of the internal joints are faulty, it is necessary to carry out independent repair of the gearbox. But before replacing them, you need to completely change the oil. The front wheel drive is completely disconnected.

Three axes are present on the shift system. One axis is equipped with a three-arm lever for selecting and disengaging gears. There is no gearbox on the second axle, but there are brackets that block rotation. After every 75 thousand kilometers, this design is completely changed. Gearbox lever play should also alert you, as should failure of other parts.

Oil leaks and breakdowns

The first thing a novice motorist needs to remember is that it is very difficult to repair a gearbox on your own. This transmission unit has a rather complex design, and any mistake in repair can lead to an accident (and additional waste of money, time and nerves). But the main points regarding gearbox repair are still worth listing. At least in order not to pay at a car service center for incorrectly done repairs.

But it’s worth understanding the signs and causes of breakdowns in the Lada Kalina manual transmission, and the main methods for eliminating them:

• Noise and knocking heard from the gearbox. If the circumstances are successful, the problem here will be the exhausted life of the lubricating fluid. A more unpleasant option is that the bearings or gears have worn out. In the described case, only replacing parts will help. And it is not recommended to change it yourself - only with the help of a professional and under his direct supervision.
• Gears are switched with some difficulty. In the described case, the problem is incomplete disengagement of the clutch (the disc does not release completely), deformation of the gear shift drive rod, wear of the plastic parts of the shift mechanism, or loosening of the screw fastenings of the lever. The last two cases are the most common. Breakdowns are corrected as follows: if there are problems with the clutch disc, there is only one recommendation - contact a specialist (self-repair is impossible without special tools and skills);
• if the rods are deformed (their appearance is shown in the service book), they must either be straightened (leveled to the required level) or replaced entirely by purchasing spare parts in advance;
• Breakages of plastic parts are corrected by replacing them. But you should take into account that replacing certain parts takes a lot of time and is impossible without the help of an AvtoVAZ car repair specialist;
• loose fasteners can be corrected most easily - you need to screw in the screws and bolts that hold the mechanism in the desired position. Standard wrenches and screwdrivers are used here. But it is recommended to purchase the appropriate set in advance, since the fasteners in the mechanism are of different sizes and for different tools.

Separately, it is worth describing the problem with oil leakage in the manual transmission in the Lada Kalina. There are two likely sources of the problem: sealant damage or oil seal wear, or a crack in the transmission housing. The second case is less common, but in this case it is often necessary to change the entire manual transmission (and this is a considerable expense). And if the sealant is damaged or the seals are worn, the box is pulled out, disassembled (with certain technical knowledge, even a beginner can do this), and either the gaskets are changed or a new sealant is applied.

There is an additional reason for oil leakage - loosening of the gearbox mounts. It can be solved by simply tightening the bolts. And if resolved in a timely manner, it can be eliminated easily and without any problems.

How does a manual transmission work?

The mechanical gearbox device in the Lada Kalina 2 consists of several main structural components. These should include:

• unit crankcase with shafts and gears;
• clutch housing;
• back cover.

The plug for draining used lubricating fluid is equipped with a special magnet. It is necessary to collect metal shavings, the formation of which is observed during the natural wear of gears and other crankcase elements.

The system also has two types of bearing designs, both roller products and ball components. The developers placed a special type of oil sump near the front bearing, from which the fluid is directed to the gear shafts and other elements of the system.

At the factory, oil intended for transmission units is poured inside the new box. This fluid must be replaced periodically. This is recommended to be done every 70 thousand km of the distance traveled. The owner should also be inclined to periodically check the lubricant level and, if necessary, top up to the required volume.

To monitor the level in the unit there is a special probe. It allows you to easily verify that there is enough oil inside the box. We act like this. Carefully insert the dipstick into the funnel and then remove it. On the measuring section of the probe there are a pair of marks indicating the maximum and minimum limits of the filled volume. If the amount of lubricant is not enough, then add it without haste.

When there is a need to replace the entire volume of lubricant, it would be better to carry out this procedure in a professional service environment. Alternatively, you can resort to the replacement process yourself. You will need to drain the oil through the hole present on the crankcase, which is closed with a special plug.

A little about oil

The Lada Kalina has a conventional five-speed manual transmission. It has been set since the days of the “nines”. Not long ago, Avtovaz released a VAZ-2180 gearbox with a cable drive. Oil is poured into the pan, it does not splash out and is not pumped up by the pump. Lubrication occurs in this way: the gears of the intermediate and other shafts are dipped into the bath during rotation, thereby ensuring lubrication of the rubbing elements. Transmission fluid also provides heat removal, otherwise the box will quickly overheat. If the gears run dry, a large amount of wear occurs. After this, it accumulates in the oil, giving the liquid a brown tint over time. Therefore, it is necessary to keep the oil level in the gearbox under control. For this procedure, Kalina has a special probe. If the oil level is below the average mark, it is better not to use the car, but to add transmission fluid.

Replacing the electric window

If the window lift cable on a Lada Kalina car has become unusable or the motor has burned out, the ESP must be changed. We carry out the replacement operation in the following order:

• dismantle the power window control unit;
• remove the door trim;
• to disconnect the window regulator from the glass, the latter must be raised all the way up;
• unscrew the four bolts that secure the glass to the ESP (two in the front and two in the back). The glass is held on by seals, but it can also be secured so that it does not fall down;
• unscrew the black metal strip (three screws);
• unscrew the eleven window regulator fasteners (10 bolts), disconnect the power plug from the electric motor;
• We begin to remove the power window from the rear, first removing one half of it;
• then we take out the front part along with the motor from the door cavity;

A burnt-out electric motor on a lift can be easily replaced. For this:

• unscrew the three studs on the mechanism body, then four more screws;
• dismantle the motor, holding the cable spool with your hand, install a new part;
• We install the window regulator in the door, connect it to the glass guides, and put the trim in place.

Identifying and eliminating gearbox problems

Servicing the gearbox involves removing this device from its original location. Especially for this, the car needs to be placed in an inspection hole or use a lift. To remove the box, you need to remove the air filter, starter, mudguard, crankcase protection, wheel drive, suspension mounts, disconnect the jet rod, front wheel drives, mounting bolts and nuts. Transmission repair may also involve replacing the rocker.

https://youtube.com/watch?v=Eq0TmNJAmZ0

During diagnostic work, all components of the gearbox control drive are checked, from the shift lever to the control rod

Attention must be paid to the gearbox fork. This component of the gear shift mechanism is made of durable material

The fork has two branched tines and an axle. If it becomes deformed, the part should be replaced.

https://youtube.com/watch?v=64VfNjK9KKg

Lada Kalina can be repaired with your own hands. In particular, one of the ways to restore the performance of the gearbox is to change the gearbox oil. It is possible to independently determine the oil level using the control marks that are placed on a special indicator. As for the use of transmission fluid, you should choose a fuel that does not lose its properties over a wide temperature range. In particular, it can be 75W-90, 80W-85 oil.

https://youtube.com/watch?v=QnyWekIwIk0

It is possible to eliminate noise from the gearbox if you replace the bearings. Repairing the Kalina gearbox can involve replacing the internal joint seals. If the seals are worn out, then because of this the owner of the Lada will be faced with such a manifestation as an oil leak.

Disassembly and assembly process

Before disassembling, the Kalina gearbox is washed with water and installed on a stand. Dismantle the engine mount bracket and the clutch cable fixation. Then remove the rear crankcase cover. After locking the input shaft, unscrew the nuts and bolt securing the fork. The spline is removed from the secondary shaft. The gear is pressed out from the input shaft. Using a drill-driver, unscrew the screws that secure the thrust plate. The next stage involves removing the mounting rings from the shafts and bearings. If the retainer plugs are unscrewed, then remove the retainer balls and springs, then remove the crankcase.

When assembling the gearbox, the threads in the hinge and lever hub, including the fixing screws, are degreased. A special adhesive is applied to the screw threads. The lever and hinge fixing screws are different lengths. The tightening torque of this element is 33.6 N.m. The installation of oil seals of various mechanisms and the Kalina rocker is carried out using a special lubricant, which is applied to the working surfaces of these elements.

Installation of the rod into the crankcase requires inspection. The hinge flange must fit inside the cover along the entire perimeter. Lubricant is placed in the ball joint of the corresponding lever. Each fastener is tightened to a certain point. When assembling the secondary shaft, you will need to replace the retaining rings. Their installation involves pressing the rings into the groove. The internal element must be pressed all the way into the retaining ring.

During the inspection, gearbox parts are cleaned. This work is carried out using a scraper or brush. All deposits are removed and the holes are cleaned of dirt. The holes are washed and blown with a stream of compressed air. Auto mechanics recommend thoroughly blowing out the bearings. To do this, the air flow must be directed in such a way that the rings do not rotate quickly. The crankcase connector, clutch and rear cover are cleaned of sealant. The properties of the magnet are checked. If the performance is weak and there are cracks on the surface of the magnet, it is replaced with a new one.

Gearbox lever jammed

In any case, it is necessary to remove the last fastener after the bolt nut securing the left suspension arm has been unscrewed to the body bracket.

After this, all that remains is to remove the lever. Another rather important element is the gearbox fork; its condition must also be monitored.

You will need to drain all the remaining oil into the container. A complete gearbox repair also involves removing such parts as the wheel drive from the gears of the differential axle shafts. The plugs are placed in the place where the gears used to be. After the gearbox adjustment is completed, they usually proceed to installing the left suspension support and brackets for the rear of the car.

Any such work, including repair of the secondary shaft, must take into account the general design of the gearbox and the basic principle of its operation. It contains a book on repairing the box. The same applies to the functionality of the component elements, otherwise the gearshift lever support cannot be replaced, like other parts.

Dismantling of the Lada Kalina gearbox at a specialized service station.

The features of the repair are fully familiar only to real professionals. It is better to entrust the work to them if you do not have the proper experience or some practical skills.

It is necessary to completely rinse the mechanism with water before disassembling it to identify a gearbox malfunction. Problems during repair may arise if the part itself is not installed on a special stand. The bracket, which is responsible for fixing the clutch cable and engine suspension, is completely dismantled.

Many people give useful advice on replacing a VAZ gearbox. According to them, in any case you will need to remove the rear cover of the crankcase.

Recommendations for the use of transmission oils for Kalina

Adding oil or replacing it in the Kalina gearbox will require an answer to the question of which substance to choose. It is better to build on the manufacturer's recommendations. The machine's operating manual provides a list of different oils. They are classified by:

• brand;
• viscosity grade (SAE);
• API group;
• to the manufacturer.

It is important which substance ensures stable operation of the gearbox in the widest temperature ranges. This is oil with viscosity marking 75W-90

It guarantees lubrication of components at temperatures from -40° to +45°.

Which gear oil has more universal properties? This can be considered a substance whose viscosity is designated 80W-85. If Kalina’s gearbox is filled with this oil, then normal operation of the units is maintained in climatic conditions from -26° to +35°.

How to check the release bearing on Kalina and how malfunctions manifest themselves (noisy or buzzing)

To understand whether your Kalina needs to replace the clutch, you must first respond in time to signs of failure and diagnose the unit. Signs of a malfunctioning Kalina release bearing:

• Noise or hum when pressing the pedal (damaged, insufficient lubrication or jammed);
• Difficulty pressing the pedal occurs when the coupling ear is broken, as well as the spring is deformed;
• These videos clearly show when the Kalina release bearing is faulty (noise, buzzing, knocking, creaking), as well as how to check the release bearing.

Manual transmission 2181

Unlike its predecessor, the new gearbox has received a lot of innovations. This box was the first for AvtoVAZ to undergo computer modeling; a similar approach to production and engineering made it possible to optimize the design and make it more reliable. The oil sump of the new gearbox has changed from 3.3 liters to 2.2 liters and the oil used is not outdated “mineral water”, but good “semi-synthetic” whose service life is designed for the entire life of the car, namely 5 years or 200 thousand kilometers .

But, undoubtedly, the most important and significant change was the introduction of gear shift cables instead of metal rods. This solution made it possible to completely remove vibration from the gearshift lever, qualitatively increase the clarity of gear engagement and their selectivity, and reduce the lever strokes.

The filling of the new box has also changed. The gear part, namely the primary and secondary shafts, remained unchanged; new multi-cone synchronizers were introduced in first and second gears. Unlike classic synchronizers, the new type of synchronizers are much more reliable, and since, according to statistics, the first and second gears are the most loaded, this solution made it possible to increase the reliability parameter of the new unit. Also, synchronizers of this design simplify gear shifting, making it even smoother. In addition, the car plant’s plans include installing this gearbox on more powerful engines, which means a clutch with a larger diameter is required. Unlike its predecessor, the new clutch has a size of 215mm (approx. It was 200mm), this entailed changing the clutch housing and relocating the starter.

The next change will be especially noticeable at subzero temperatures. In old-type boxes, the gear selection mechanism was located at the bottom and was in oil. When the temperature dropped below zero, the oil thickened and engaging gears until the oil warmed up was difficult. In the new model gearbox, the gear selection mechanism is a separate module located outside the gearbox - this solution made it possible to get rid of the problem of difficult shifts in cold weather during the first kilometers of the journey, and also in the future greatly simplifies the process of repairing and servicing the gearbox. There is protection against erroneous engagement of reverse gear, which can only be engaged in neutral.

Through an integrated approach to the development of a new gearbox, engineers managed to achieve a level of gearbox operation no worse than that of competitors in the price segment. AvtoVAZ plans to introduce multi-cone synchronizers in third gear, as well as switch to a hydraulic clutch drive.

Choosing the best

At the factory, TNK TRANS KP oil is poured into the car's gearbox, but the overwhelming majority of car owners prefer to fill in fluids from other brands, most often foreign-made. Usually, when switching to oils from other brands, the noise coming from the gearbox is reduced, service life is increased, and even fuel consumption is reduced.

To select oil for the Lada Kalina gearbox, you need to focus on viscosity. The following list will help you here:

• Viscosity grade: 75W80 withstands temperatures from -40 to +35
• Viscosity grade: 75W85 can withstand temperatures from -40 to +35 (but in terms of characteristics it is slightly ahead of the competitor)
• Viscosity grade: 75W90 withstands temperatures from -40 to +45
• Viscosity grade: 80W85 withstands temperatures from -26 to +35
• Viscosity grade: 80W90 withstands temperatures from -26 to +45
• Viscosity grade: 85W90 withstands temperatures from -12 to +45 and above