Removal, disassembly and repair of the VAZ-2107 gearbox

The gearbox is one of the most important components of a car, the smooth operation of which determines the durability and reliability of the car. If it becomes necessary to remove the gearbox to replace it or carry out repair work, you should be sure that in this case it is impossible to do without dismantling the gearbox, since removing the gearbox is a rather complex and time-consuming process, especially if it is performed for the first time. Replacing or repairing a gearbox at a service station is an expensive undertaking, so many owners of VAZ-2107 cars prefer to carry out this work themselves. What should a car owner know who will remove the G7 gearbox for the first time without outside help?

• Fastening the VAZ-2107 gearbox
  Video: how to remove and replace the VAZ-2107 gearbox cushions

Removing the manual transmission

In any case, in order to repair the VAZ-2107 gearbox, you will need to remove it from the car. And in order to do this, you need to drive the car onto an inspection hole or overpass.

The first step is to remove the rod from the gear shift lever. After this, you need to use a screwdriver to unscrew the screws of the cover that covers the hole in the floor of the car body. At this point, the work inside the cabin is completed; all subsequent removal steps are carried out from below the car.

While under the car you need to:

1. Remove the exhaust pipe;
2. Then the starter is unscrewed and removed from the flywheel housing;
3. The driveshaft is disconnected from the gearbox.

To make it easier to remove the box, you need to disconnect the cross member of the rear engine mount and the speedometer drive cable.

Next, the clutch hydraulic cylinder is disconnected from the gearbox. It is important that when disconnecting the cylinder, you do not accidentally remove the hydraulic hose from it.

After this, you need to unscrew the bolts that secure the clutch housing cover (10 wrench). Next, they begin to directly remove the box, and since its weight is significant, you need to install a reliable support under it.

Then, using a socket wrench, unscrew the bolts that secure the clutch housing to the engine. Now, in order to remove the box, you need to carefully move it back, gradually removing the input shaft from the hub of the clutch driven disc.

This must be done carefully to prevent the driven disk from moving, otherwise it will be difficult to install the box in place. In principle, the removal work has been completed, and the VAZ-2107 gearbox can be repaired.

Also read - Automatic transmission repair, repair features.

Disassembling the box

Increased noise of the gearbox can be caused by wear or failure of its shaft bearings, as well as significant wear of gears and synchronizers. To determine what is causing the increased noise, you will need to disassemble it.

This work is quite complex technologically, and if the car owner is not confident in his abilities, then it is better to contact a specialized service station, otherwise in the future, incorrect assembly can lead to more significant consequences, or to the fact that the gearbox will not work.

But, if you decided to repair the VAZ-2107 gearbox yourself, then this will require a set of keys and sockets, a powerful screwdriver, and pullers for removing bearings.

Operating procedure.

First of all, unscrew the nuts that secure the shift lever housing and remove the lever from the box.

Then the exhaust pipe mounting bracket is removed. After this, the bolts securing the rear and bottom covers of the box are unscrewed. This will be enough to visually determine the condition of the gears and synchronizers.

If significant wear is noticed, then most likely the reason for the increased noise in them. But it is also worth checking the box shafts for axial displacement. If there is one, then the bearings are also very worn and require replacement.

To carry out work to replace worn parts, a complete disassembly of the gearbox will be required. To do this, first remove the back cover by unscrewing the nut securing it, access to which is possible after removing the bottom cover.

To make it easier to remove, you will need to move the 1st-2nd gear slider down. Then, lightly tapping the lid, remove it from the studs.

To gain access to the 5th gear and reverse bearing, you need to press out the plug. After which the 5th and reverse gear block is removed.

Using a puller, the bearing and the secondary shaft oil seal are carefully removed from the cover housing. If they show signs of noticeable wear, they are replaced with new ones.

REPAIR

The VAZ 2107 has a 5-speed gearbox, which, despite the comparative simplicity of its design, can become unusable for reasons classic for manual transmissions:

• wear and tear due to natural reasons: high mileage, irregular operation and depletion of the service life of components, weather conditions not meeting the desired ones, and as a result - a decrease in service life, etc.;
• non-compliance of the working fluid with standards suitable for normal operation of the transmission;
• non-original spare parts included in the box;
• damage to the gearbox housing due to mechanical impact;

When it comes to the gearbox, even if it is a Zhiguli, the best option would be to entrust diagnostics and maintenance to specialists at a service station. Fortunately, repairing it will not cost too much, except in rare cases that require a complete replacement of the entire mechanism, when it would be more advisable to purchase the same new car.

Further disassembly

To further disassemble the box, the clutch housing is disconnected from it. This will allow access to the front cover seal of the box. If oil leakage is noticed, the oil seal must be replaced.

Next, unscrew the front cover bearing bolt, the gear block bolt and the intermediate shaft mounting bolt. After which the plate is unscrewed, under which there are springs and slider clamps.

The springs and retainers are also removed, it is important to note which spring was in which socket, since the spring for 5th gear and reverse is slightly longer.

After these procedures, the gear block is removed. But before that, you need to remember the location of the spacer rings. First, the 5th gear gears are removed along with the shift rod. In most cases, gears have travel stops in the form of locking rings; they must be removed carefully.

Then the rear bearing of the intermediate shaft is removed and this shaft is removed from the housing. After this, the slider responsible for engaging 3rd and 4th gears is removed from the body, having previously unscrewed the bolt securing the shift fork from it.

In the same way, the 1st and 2nd gear slider is removed. When removing them, it is important not to lose the locking blocks located in the box housing.

Having finished with the sliders, you can remove the input shaft. The next step is to remove the locking plate, behind which is the secondary shaft bearing.

After removing it, it will be possible to remove the secondary shaft. Disassembly is complete.

Secondary shaft

It is a continuation of the primary in space. It contains gears of the first (23), second (24) and third (25) gears, which move freely and in certain positions engage with the corresponding gears of the intermediate shaft 1. All gears have different diameters, which ensures a change in the amount of transmitted torque .

The secondary shaft rotates on bearings 9, 11 and 12. The first of them is roller, installed in the primary shaft, the rest are pressed into the crankcase and the rear cover, respectively.

Increased noise

After disassembly, you need to troubleshoot the box parts. If severe wear of the gear teeth is noticed, they must be replaced. It is better to replace gears one by one. So as not to confuse the gears.

Many gears have retaining rings. Synchronizers also undergo the same troubleshooting. If they notice even slight wear or damage, they are replaced.

Particular attention should be paid to the condition of the bearings. They should not have any play or the appearance of deep treadmills of balls.

Although, even if the bearing looks good on the outside, it is better to replace it. This eliminates the possibility of noise occurring after the box is assembled.

Spontaneous speed shutdown

If the repair of the VAZ-2107 gearbox is associated with the spontaneous shutdown of any gear, then in this case the sliders and clamps need close attention.

It is necessary to inspect the condition of the fastener seats. If the edges of the seats are heavily worn, then the sliders need to be replaced.

Another method of restoring seats is used by some craftsmen. To do this, a layer of metal is applied to the seats using a welding machine. And then, using a grinder, new seats are cut out in the applied metal.

The method is quite simple, but not very effective, since the applied metal is softer in structure, which means it will wear out much faster.

It is advisable to replace the clamps during repairs, as well as the springs that press them to the slides.

This is done because the springs are constantly pressed and shrink over time, which is why they do not create the required force on the clamps.

VAZ-2107 input shaft bearing: number, price, which one is better to buy, size (5 mortar, 4 mortar)

In the “Classics” manual transmission, the designers provide a radial open single-row ball bearing of class 6 accuracy, which absorbs 90% of radial loads. To select this spare part, you need to pay attention to the radial and axial clearance, ease of rotation, appearance of the product (no corrosion, cracks, nicks, cavities). Before you buy a gearbox input shaft bearing for the “seven”, check out the list of recommended manufacturers. The listed manufacturers produce high-quality products at reasonable prices with exact dimensions in accordance with GOST 520-211.

• Open: 6-50706AU (replaceable without disassembling the gearbox)
• Closed: 6-180502K1US9 (replaceable with disassembling the gearbox)

Table of costs and recommended manufacturers

List of a complete set of gearbox bearings for the VAZ 2107

Bearing size table 6-50706AU

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.