6.2. Transmission

Possible malfunctions of the transmission and ways of their elimination 
Features of maintenance of the transmission 
Repair of the transmission 



On the Gazelle cars the five-high-speed transmission is installed. Weight (without gas station) — 32 kg.
Existence of the 5th raising transfer provides in actual practice to operation saving 0,7 — 1,0 l of fuel on 100 km of a run in comparison with the 4-speed transmission, the maximum speed of 115 km/h, reduces engine turns at high speeds of the movement of the car, increasing its durability.

Fig. 5.13. Transmission (longitudinal section): And — the two-conical synchronizer; 1 — a main shaft; 2 — a cover of the bearing of a main shaft; 3 — an epiploon; 4 — the ball bearing of a main shaft; 5 — a lock ring; 6 — the roller bearing of a secondary shaft; 7 — сапун; 8 — the blocking ring; 9 — the inclusion coupling; 10 — a synchronizer cracker; 11 — a nave of the coupling of inclusion of the 3rd, 4th transfers; 12 — a gear wheel of the 3rd transfer; 13 — the needle bearing of a gear wheel; 14 — a lock ring of half rings; 15 — a half ring; 16 — a gear wheel of the second transfer; 17 — a lock ring; 18 — a gear wheel of the 1st transfer; 19 — a secondary shaft; 20 — a backing gear wheel; 21 — a fork of inclusion of the 5th transfer and a backing; 22 — a nave of the coupling of inclusion of the 5th transfer and a backing; 23 — a bolt of fastening of a plate of a clamp; 24 — a plate; 25 — a spring of clamps; 26 — a ball of clamps; 27 — a spring of the blocking plug; 28 — the plug blocking; 29 — a head of a rod of inclusion of the 5th transfer and a backing; 30 — the switching lever case; 31 — a gear wheel of the 5th transfer; 32 — a washer persistent; 33 — the plug expansion; 34 — a transmission case back; 35 — an epiploon; 36 — an axis of an intermediate gear wheel of a backing; 37 — the needle bearing of an intermediate gear wheel of a backing; 38 — an intermediate gear wheel of a backing; 39 — a pin; 40 — a bolt of fastening of the plug of an axis of an intermediate gear wheel of a backing; 41 — the plug of an axis of an intermediate gear wheel of a backing; 42 — the ball bearing of a secondary shaft; 43 — a ring lock the bearing of a secondary shaft; 44 — a ring lock; 45 — the bearing; 46 — a stopper masloslivny; 47 — the block of gear wheels; 48 — a stopper oil-filling; 49 — a transmission case forward; 50 — adjusting laying




The case of the transmission is made of aluminum alloy and consists of two parts — forward 49 and back 34 cases (fig. 5.13). Cases for ensuring necessary coaxiality of support of shaft and openings under rods of the mechanism of switching are aligned on the adjusting plugs pressed in a forward case and connect with each other ten bolts.
The gear wheel of a main shaft, and also gear wheel of the 1st, 2nd, 3rd, 5th transfers and backing established on secondary to a shaft 19 are in continuous gearing with gear wheels of the block of gear wheels 47, have slanting teeths and rotate on needle bearings with plastic separators. The intermediate gear wheel of a backing rotates on bulk rollers with a diameter of 3 mm on an axis which support settle down in both cases.
All transfers are supplied with synchronizers of inertial type which gear wreaths connect to gear wheels by means of small shliyets. Synchronizers of the 3rd, 4th, 5th transfers and a backing have the gear wreaths executed at the same time with cones. Alignment of turns, necessary for unaccented gear shifting, of the included gear wheel to turns of a secondary shaft is reached by means of the brake moment arising at the expense of friction forces on an external surface of a cone of a gear wreath of a gear wheel and an internal conical surface of the external (blocking) ring of the 8th synchronizer connected through naves 11 and 22 to a secondary shaft 19.

Fig. 5.14. The two-conical synchronizer 1 — the 2nd transfers: 1 — the coupling; 2 — a nave; 3 — a secondary shaft; 4 — a gear wheel; 5 — a synchronizer cracker; 7 — a gear wheel of the 1st transfer; 8 — a ring internal; 9 — a ring average; 10 — a gear wreath; 11 — a ring external




The synchronizer 1 — the 2nd transfers — two-conical, has the increased brake moment at the expense of the additional surface of friction formed by an external conic surface of the internal ring of 8 (fig. 5.14) connected with a nave and an internal conic surface on an average ring of the 9th synchronizer connected by three ledges (ledges enter openings on a gear wreath 10) with the included gear wheel.
It should be noted that till 01.06.03 in the transmission the one-conical synchronizer unified with synchronizers of the 3rd, 4th, 5th transfers and a backing was installed. Inclusion of transfers is made by connection of internal teeths of couplings 9 (fig. 5.13) with external gear wreaths of synchronizers. Lateral faces of teeths of couplings and wreaths of synchronizers are slanted inside at an angle 4 ° and at the included situation form the lock interfering self-switching off of transfers. Ledges on teeths of wreaths of synchronizers limit movements of couplings at inclusion of transfers.
Axial forces from slanting teeths of gear wheels of a secondary shaft are perceived by lock rings 17 and 44, a persistent washer 32, burty a secondary shaft and two persistent half rings located in a flute on secondary to a shaft which are covered by a ring 14.
Ball bearings of primary and secondary shaft are installed on shaft by means of spring and lock rings and are fixed in cases by means of external lock rings.
The block of gear wheels rotates on the ball or conic bearings installed in deaf nests of forward and back cases.

Fig. 5.15. Gear shifting mechanism: 1 — a forward case; 2 — a fork of inclusion of the 1st and 3rd transfers; 3 — a bolt of fastening of a fork of inclusion; 4 — a fork of inclusion of the 1st and 2nd transfers; 5 — a rod of inclusion of the 1st and 2nd transfers; 6 — a rod of inclusion of the 3rd and 4th transfers; 7 — a finger; 8 — a plunger; 9 — a rod of inclusion of the 5th transfer and a backing; 10 — a fork of inclusion of the 5th transfer and a backing; 11 — a clamp ball; 12 — a clamp spring; 13 — a bolt of fastening of a plate; 14 — a plate; 15 — a spring of the blocking plug; 16 — the blocking plug; 17 — a head of a rod of inclusion of the 5th transfer and a backing; 18 — the switching lever case; 19 — the switching lever — the lower part; 20 — the locking plug; 21 — a rubber pillow; 22 — the expansion plug; 23 — a persistent cone; 24 — the switching lever — the top part; 25 — the switching lever handle; 26 — a body floor sealant; 27 — a protective sealant; 28 — a lever spring saddle; 29 — a lever spring; 30 — a cap; 31 — a pin; 32 — a safety lock; 33 — a safety lock spring; 34 — a head of a rod of inclusion of the 1st and 2nd transfers; 35 — a restrictive pin; 36 — a back case; 37 — the backing light switch; 38 — a fork cracker




The pretightness is carried out by statement at assembly of adjusting laying 50 in a nest of a forward case. Wreaths of gear wheels of continuous gearing of the 2nd, 3rd and 5th transfers of the block of gear wheels are put with a tightness on an intermediate shaft on which the long teeths serving at the same time as wreaths of gear wheels of the 1st transfer and a backing of the block of gear wheels are cut. The head of axis 36 of an intermediate gear wheel of a backing is established in a bed of a back case of the transmission and fastens in it a lock bolt. The opposite end of an axis enters the plug 41, is fixed in it by a cutting elastic pin, the plug fastens to a bed in a forward case also lock bolt. The mechanism of switching contains rods on which forks of gear shifting and a head 29 in which grooves the lower end of the lever of switching settles down fasten. Fixing of rods in the switched on and off situation is carried out by means of balls of 11 (fig. 5.15) and springs 15. The blocking device consisting of two lock plungers and a lock finger protects a box from simultaneous inclusion of two transfers. Besides, between a head of a rod of inclusion of a backing and a wall of a back case the blocking plug 16 with a spring 15 which makes impossible casual movement of the lever of switching from the provision of the included 5th transfer to the provision of a backing settles down. The lever of gear shifting is supplied with the damping device eliminating its tinkling sound at a resonance on big turns of the engine and settles down in the special case 18 fastening to a back case from above. By means of springs and safety locks the lower head of the lever of switching in neutral situation always settles down in a head of a rod of inclusion of the 3rd and 4th transfers.
The Masloslivny stopper of 46 (fig. 5.13) has the magnet catching the small parts of metal which are contained in oil — products of wear of details of the transmission.
Five-high-speed transmissions for the Volga cars and the Gazelle cars are unified on the majority of details. The transmission of the Gazelle cars differs in a main shaft (number of teeths 25 instead of 26), a mounted wreath of the drive of the block of gear wheels (36 teeths instead of 35) and a speedometer drive gear wheel, higher case of the lever of switching and the lower part of the lever of gear shifting.