UAZ gearbox
Many owners of domestic cars often encounter malfunctions in the gearbox on their UAZ. But the Russian person is designed in such a way that he always prefers to postpone repairs until later. As a result, the UAZ gearbox lever often begins to act up.
The rumble of gears is constantly heard from the transmission, and sometimes the box stops responding altogether. It's time to start repairing it or replacing it with a more advanced one, for example, an ADS checkpoint or a Daimos checkpoint.
Five-speed gearbox for UAZ Patriot
The Russian organization Avtodetal-Service (ADS) specializes in the production of gearboxes for UAZ vehicles. The 5-speed ADS Expert gearbox is supplied to the Ulyanovsk Automobile Plant, where it is equipped with current models of domestic SUVs. It is a one-piece crankcase and is synchronized in all frontal gears.
The gearbox is equipped with both a spur and helical transfer case. Modern ADS Expert boxes have the following features.
- By increasing the length of the gear shift lever, the gearbox mechanisms function more smoothly.
- The redesigned transfer case rod is equipped with a handbrake return spring mounting bracket, making it much easier to assemble the transmission during installation.
- The general design of the gearbox and the selective gear change device have changed somewhat. This made it possible to prevent oil leakage and protect the gearbox casing from the penetration of earth and water.
- A special sensor is built into the design, which ensures uninterrupted power supply to the rear lights.
- The filling hole of the gearbox chamber is shifted 2 cm lower. This is done to improve oil circulation inside the gearbox. It is completely prevented from getting into the transfer case.
In addition to ADS Expert, in 2013 an improved version of the gearbox from Daimos, based on electric control, was developed for the UAZ Patriot. This made it possible to completely eliminate the use of the RCP lever. Instead, a special washer is built in. The rear propeller shaft has also changed: it has been shortened and the intermediate support has been removed.
Transmission repair
The 5-speed Daimos gearbox is also suitable for other UAZ models, which include Simbir, Hunter and UAZ-3160.
To install a new type gearbox on the UAZ Hunter, you will need to change the floor hatches of the car body to more modern ones. The remaining 2 car models will require a little modernization, since it is necessary to cut a hole in the floor for the gearbox lever.
When carrying out installation work, qualified assistance will be needed, so it is recommended to entrust the replacement of the gearbox to a licensed service station.
If you want to replace some gearbox parts yourself, use the instructions provided for complete disassembly and reassembly of a UAZ gearbox. In this case, repairs can be carried out without the use of a lift or outside help.
Necessary tools and preparatory work
Dismantling the UAZ gearbox will require the following tools and materials:
- a set of open-end and socket wrenches in sizes from 10 to 36;
- a special wrench for tightening flattened nuts (you can use a bicycle wrench);
- a set of Phillips and flat screwdrivers;
- service key with straight and curved ends (pliers);
- copper synchronizer or rod for working with gears;
- a small piece of metal pipe to hold keys when screwing nuts in hard-to-reach places;
- core chisel and heavy hammer;
- set of gaskets for UAZ gearbox;
- high-quality sealant that will be used to install gaskets.
When choosing a set of keys, it is important that they are as compact and thin as possible. Most fasteners are in an inconvenient position for dismantling, so choosing the right keys will save you time and nerves.
It is advisable to take gaskets for the current model, but if your car is an old model, for example, with a UAZ 3303 gearbox, any set for the previous generation of cars will do.
If there is a need to update the gearbox, you will need to buy special sets of hardware for the gearbox and transfer case. The second set may be a problem because it is not so easy to find in auto parts stores.
The UAZ gearbox diagram has its own characteristics of connecting the transfer case and gearbox. Of course, this type of design provides a huge advantage, but it is difficult to remove yourself, since the assembly weighs about 80 kg. Without outside help, you will have to lift the car using a manual winch. In this case, you need to make sure that it has reliable support. For example, a metal frame or a durable beam ceiling. The structure should easily support the weight of your car.
Before starting work, you need to place the machine on a uniform surface. Then you need to drain the oil from the gearbox and transfer case. Despite the common supply system, each of them has separate drain plugs. While the grease is flowing out, you can remove the front seats, the dashboard and 2 hatches, which are located at the bottom of the body. After the oil has drained completely, you need to return the plugs to their place.
Dismantling the unit connecting the gearbox and transfer case
Disassembled UAZ box
Start by unscrewing the frame crossbar, which is located under the handbrake system. Remove the front universal joint by disconnecting it from the transfer case flanges. Disabling the front axle clutches will help facilitate this process. The rear driveshaft must be removed from the top side of the body.
The clutch system must be dismantled, you should start by unscrewing the fasteners of the input shaft splines, while the hose is pushed inside the bell. Unscrew the 4 bolts that hold the clutch fork casing and remove the spring. Then unscrew the function cylinder controller and pull out the plug.
The transfer case and gearbox will need to be well wrapped with a cable or rope and left for a while. Unscrew the cushion mounts and hardware holding the gearbox to the bell. This is done gradually and evenly. You can completely unscrew the bolts and nuts only if the box has moved slightly away from the bell. It is recommended to make a temporary support for the car engine using a jack, otherwise its lower part will hang and get in the way. Once the transmission has been successfully disconnected, it can be completely removed.
Worn parts inside the bell are best replaced with new ones. This is especially true for studs, as their threads wear off very quickly.
Where to start dismantling the gearbox
Remove the handbrake lever so that it is not in the way. After this, unscrew the hardware connecting the gearbox and transfer case. Most often, this cannot be done in one movement, since the parts are held together with sealant. You'll have to hit the knot really hard to separate them. It is very important to keep track of spare parts; after disconnection, nothing should be lost. It is advisable to place them in one container and set them aside until assembly.
The transmission and transfer case should be inspected for worn parts. To disassemble these parts, you need to try hard, since the bolts and nuts are in hard-to-reach places.
The input shaft has a roller bearing that does not have a race, so in most cases it falls apart when dismantled. After assembling it, you need to pay attention to how the last roller is placed. If the roller fits in easily, it will have to be replaced, as this indicates wear of the part.
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It is distinguished from a 4-speed by the presence of synchronizers in all gears. The box has much smoother shifting. Dynamic characteristics have been improved. The car picks up speed faster. The overall noise during operation has been reduced, resulting in improved acoustic comfort and reduced vibrations. The UAZ 5-speed ADS gearbox is relatively easy to repair. Thanks to 5 gears and improved engine performance, it was possible to reduce fuel consumption by as much as 20%.
By purchasing a UAZ 5-speed ADS gearbox you get approximate gearbox resource 300,000 km, which is also higher than its predecessor. The car's speed range will also expand. The box is compatible with UAZ - 3303, 3741, 3962, 2206 with engines of the Ulyanovsk Motor Plant UMZ-4178, UMZ-4213 (eng), UMZ-4218.
You can buy and install a UAZ 5-speed ADS gearbox without making changes to the design of the car.
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Rice. 189. Shift mechanism for a five-speed gearbox: 1 – shift fork for 1st and 2nd gears; 2, 12, 33 – plugs; 3, 16 – springs; 4 – clamp; 5 – drive of the rod of the 5th gear; 6 – reverse fork; 7 – gear shift lever; 8 – lever seal; 9 – pin; 10 – lever spring; 11 – lever support; 13 – reverse fuse plunger; 14 – fuse cover; 15 – ball; 17 – side cover; 18 – shift fork for III and IV gears; 19 – intermediate lever; 20 – intermediate lever plunger; 21, 25 – plugs; 22 – 5th gear housing; 23 – retainer ball spring; 24 – locking ball; 26 – fork rod of 1st and 2nd gears; 27 – fork rod of III and IV gears; 28 – intermediate lever rod; 29 – lock plunger; 30 – reverse fork rod; 31 – locking bolts; 32 – lever stop; 34 – lock washer; 35 – 5th gear shift fork; 36 – 5th gear fork rod; 37 – reverse light switch; 38 – gearbox lever mounting bolt; 39 – gear lever |
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Rice. 186. Five-speed gearbox: 1 – input shaft; 2 – front cover; 3 – cuff; 4, 18, 22, 34, 44, 47 – retaining rings; 5, 13, 19, 33, 43 – bearings; 6 – front bearing of the secondary shaft; 7 – crankcase; 8 – synchronizer clutch for 3rd and 4th gears; 9 – third gear gear; 10 – 2nd gear gear; 11 – synchronizer clutch for 1st and 2nd gears; 12 – 1st gear gear; 14 – thrust ring; 15 – 5th gear housing; 16 – spacer sleeve; 17 – driven gear of the 5th gear; 20 – thrust ring; 21 – secondary shaft; 23 – needle bearing of the 5th gear gear; 24 – bolt securing the rear bearing of the intermediate shaft; 25 – 5th gear synchronizer hub; 26 – support sleeve; 27 – disc spring; 28, 29 – washer; 30 – drive gear of 5th gear; 31 – blocking ring of the 5th gear gear; 32 – 5th gear synchronizer clutch; 35 – screw; 36 – cover of the rear bearing of the intermediate shaft; 37 – guide sleeve; 38 – reverse gear; 39 – reverse gear axis; 40 – plug; 41 – intermediate shaft; 42 – block of gears driving the intermediate shaft and III gear; 45 – cover of the front bearing of the intermediate shaft; 46 – blocking ring of the 4th gear gear |
4. Unscrew the fastening bolts and remove the fifth gear housing 15 with the rear bearing 19 of the secondary shaft.
5. Unscrew bolt 24 securing the rear bearing of the intermediate shaft (the bolt has a left-hand thread) and remove the disc spring 27 and thrust washer 28.
6. Remove the fifth gear drive gear 30 with the needle bearing 23 and the blocking ring 31 from the intermediate shaft.
7. Unscrew the locking bolt 31 (see. rice. 189) fifth gear shift forks and remove clutch 32 (see. rice. 186) with a fork. At the same time, hold the crackers, balls and synchronizer springs.
8. Using a puller, remove roller bearing 13 (without inner ring) with thrust ring 14, spacer sleeve 16 and fifth gear driven gear 17 from the secondary shaft.
9. Using a puller, remove hub 25 of the fifth gear synchronizer with thrust washer 29 from the intermediate shaft.
10. Unscrew the fastening bolts and remove the front cover 2. Then remove the retaining ring 47 of the input shaft bearing.
11. Remove covers 45 and 36 of the intermediate shaft bearings.
12. Using the M8 threaded hole in the rear end of the axle 39 of the reverse intermediate gear, press the axle back and remove the gear 38.
13. Using a puller, remove the rear bearings 5 and 33 of the primary and intermediate shafts.
14. Install the box so that the intermediate shaft is on top, move the intermediate shaft forward until the intermediate shaft gear block 42 stops in the crankcase to move the front bearing forward.
15. Move the intermediate shaft back until the inner ring comes out of the front bearing 43.
16. Install the gearbox with the hatch up under the shift mechanism.
17. Remove input shaft 1, blocking ring 46 of the fourth gear gear and the secondary shaft assembly from the gearbox housing.
18. Remove the lock ring 44 and move the intermediate shaft back until the gear block stops in the crankcase. Press the intermediate shaft out of the gear block through the front hole in the crankcase towards the rear of the transmission. Remove the intermediate shaft and gear block from the crankcase.
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Rice. 190. Secondary shaft of the gearbox assembly: 1 – secondary shaft; 2, 15, 20, 22 – thrust washer; 3 – 1st gear gear; 4 – blocking ring of the 1st gear gear; 5, 7, 11, 12 – retaining ring; 6 – synchronizer of 1st and 2nd gears; 8 – 2nd gear gear; 9 – third gear gear; 10 – blocking ring of the 3rd gear gear; 13, 21 – key; 14 – synchronizer for 3rd and 4th gears; 16 – spacer sleeve; 17 – needle bearing of the 3rd gear gear; 18 – needle bearing of the 2nd gear; 19 – blocking ring of the 2nd gear; 23 – needle bearing of the 1st gear gear; 24 – inner ring of roller bearing |
1. Remove the inner ring 24 (see rice. 190) bearing, thrust washer 2 and first gear gear 3 with needle bearing 23 and blocking ring 4.
2. Using a puller, remove retaining ring 5 of the first and second gear synchronizer hub and thrust washer 22.
3. Remove the synchronizer 6 of the first and second gears together with the gear 8 of the second gear, the blocking ring 19 and the thrust washer 20.
4. Remove key 21, retaining ring 7 and needle bearing 18 of the second gear.
5. Using a puller, remove retaining ring 12 of the third and fourth gear synchronizer hub.
6. Remove the synchronizer 14 of the third and fourth gears together with the third gear gear 9, the blocking ring 10 and the thrust washer 15.
7. Remove key 13, retaining ring 11, spacer 16 and needle bearing 17 of the third gear.
Disassembling the switching mechanism
1. Unscrew the four bolts of support 11 (see. rice. 189) of the shift lever and remove the support with lever 7 and preload spring 10.
UAZ (loaf) cars have the most spacious body. The machine body is made of durable material. The vehicle is equipped with security systems, a durable power unit that is capable of developing more than 100 horsepower, and a transmission system.
The all-wheel drive cargo-passenger UAZ, which has increased cross-country ability, began to be mass-produced at the Ulyanovsk Automobile Plant in the mid-1960s.
UAZ transmission components
The new UAZ 452 family vehicles have a manual transmission (four-speed). Inertial type synchronizers provide easier gear shifting. The five-speed ADS gearbox is synchronized in all forward gears.
The UAZ can be equipped with a 5-speed manual transmission Daimos (DYMOS). This gearbox is distinguished by its reliability. Its average service life is 300,000 km. The filler plug is located in the middle of the box, the drain is at the bottom. It seems possible to unscrew them using a hex key. When oil is drained, special containers should be prepared. New fluid must be filled to the level of the oil filler hole on the box. The dipstick allows you to accurately determine to what level the liquid is filled. An alternative to the probe can be a long nail. For preventive purposes, the oil level must be measured every 15,000 km.
The presence of mechanics on this version of the vehicle is completely justified. It is important to use such a car on rough terrain and off-road. In addition to this, there will be no problems with towing.
The gearbox has external shift levers. The lever in the cabin moves freely both parallel and perpendicular to its axis.
The machine is equipped with a transfer case. The design of the transfer case for the UAZ 452: drive axle shafts, gears. All of the listed components are located in a cast iron crankcase. The crankcase and the cover are connected with nuts. The shift fork rods are securely fixed in the cover.
There is a spline and bearings. There is a helical gear for the speedometer drive. The intermediate shaft is fixed to the “loaf” bearings. This box has reliable gears with straight teeth.
Thus, the gearbox on the UAZ 452 consists of many components and assemblies. This unit requires regular maintenance.
The need to diagnose the UAZ model 452 gearbox
This vehicle must be diagnosed if control begins to deteriorate, characteristic creaks are heard when a gear change occurs, or gears begin to change spontaneously. The UAZ transfer case should be checked if the grip of the wheels on the road has noticeably deteriorated, a hum or increasing noise has begun to appear during its operation.
During maintenance, technicians must check the system for oil leaks and lubricant levels. All worn parts in the transmission system must be replaced with new ones. Also, diagnostics involves lubricating the lever axle and adjusting the front linkages.
Routine diagnostics in a professional auto repair shop allows you to accurately determine the existing nature of the problem with the gearbox and eliminate existing problems at an early stage.
Causes of breakdowns
As a rule, the need to replace the main components of a gearbox arises due to their natural wear and tear.
Causes of gearbox breakdowns
The main reason for oil leakage from the gearbox is the presence of an increased level of fuel in the system. For UAZ gearboxes, you should use high-quality oil. If the liquid is not of the proper quality, this may cause characteristic noises from the box. When the synchronizer or its parts wear out, it is always difficult to change gears. You should also pay attention to the details of the switching mechanism. When gear teeth are deformed, gears often switch off automatically.
Transmission removal process
It is quite possible to repair the gearbox on a UAZ 452 yourself. This requires:
- a set of wrenches, including the keys needed to tighten the nuts;
- screwdrivers;
- hammer;
- chisel;
- pliers.
Dismantling algorithm.
The car must be parked on level ground. It is necessary to drain the oil from the two boxes by unscrewing the drain plugs. Next, the front seats, hatch halves, clutch release fork, transverse frame, and gear shift levers are removed.
The speedometer shaft, suspension supports in the chassis, and brake system levers must be removed. As a result, the exit to the clutch housing opens. The box is fixed on it with fastening nuts, which must be unscrewed, then the UAZ gearbox along with the transfer gearbox is carefully pulled out until the spline shaft exits the flywheel. The driver will need an assistant to remove the box.
Assembling a UAZ gearbox requires due attention. During self-assembly, the driver may have difficulty installing the input shaft into the clutch system. During this process, it is necessary to actively move the box so that the shaft gets into the splines.
As soon as disassembly into individual component parts has occurred, the box must be washed in kerosene and dried. All spare parts are checked for integrity. First of all, this concerns the crankcase and shafts. If the threads on the shafts are damaged, they need to be replaced. It seems dangerous to operate the machine if there are chips on the gears.
Thus, timely repair of the UAZ “loaf” gearbox helps to extend the service life of the gearbox.
About the book: Manual for ADS EXPERT gearbox for UAZ. 2007 edition.
Book format: pdf file in zip archive
Pages: 19
Language: Russian
Size: 6.9 MB
Download: free, no restrictions or passwords
Five-speed ADS EXPERT gearbox, manufactured by Avtodetal-Service OJSC, mechanical, synchronized in all forward gears, in a solid housing 420.3181-1700010-02 or 420.3182-1700010. The gear shift pattern is classic.
Application of the ADS EXPERT five-speed gearbox:
Gearbox 420.3181-1700010-02 is designed for installation on passenger cars of the UAZ-3160, UAZ-3162 Simbir family, with gasoline engines ZMZ-409, UMZ-4218 and diesel engines ZMZ-514 and Andoria.
Gearbox 420.3182-1700010 is designed for installation on passenger-and-freight vehicles of the UAZ-3741, UAZ-3962, UAZ-3303, UAZ-3909 family with gasoline engines UMZ-4178, UMZ-4218, UMZ-4213, ZMZ-409.
In order to increase the service life of the five-speed ADS EXPERT gearbox, it was modernized:
1. The length of the gear shift lever in the gearbox mechanism has been increased. The design of the cam for returning the lever to the neutral position has been changed, which has made gear shifting clearer and easier, and eliminated the possibility of the forward and reverse gears switching off on their own.
2. The stud for the gearbox has been modified, a bracket for fastening the return spring of the parking brake has been additionally installed, and the design of the housing of the rear end of the gearbox has been changed, which has increased convenience and saved time when installing and assembling the gearbox with the transfer case.
3. The design of the selective gear shift mechanism was changed, an additional rubber seal was introduced for the lever, which eliminated the possibility of transmission leaking from under the lever. The properties of the rubber from which the boot is made have been improved, this ensures complete protection of the gearbox mechanism from dust and dirt and significantly increases the service life of the boot, and as a result, its reliability.
4. A reverse gear sensor has been installed with a reinforced design and protection from aggressive environments, this ensures uninterrupted operation.
5. The filler hole in the gearbox housing was moved 20 mm lower, an oil deflector for the secondary shaft bearing was installed, thereby ensuring better oil circulation in the unit and preventing spontaneous pumping of oil from the gearbox to the transfer case.
In addition to the above improvements, the ADS EXPERT five-speed gearbox has a number of consumer advantages:
— Extended speed range.
— Reduced fuel up to 20%.
— Installation of the gearbox is possible both with and with a transfer case.
— Reduction of noise level during gearbox operation by up to 80 dB.
— Easy and clear gear shifting.
— Wide selection of installation kits.
Contents of the manual for the five-speed ADS EXPERT gearbox for UAZ vehicles.
1. General information about gearboxes 420.3181-1700010-02 and 420.3182-1700010
2. Operational and technical characteristics of gearboxes 420.3181-1700010-02, 420.3182-1700010
3. Disassembly of gearboxes 420.3181-1700010-02, 420.3182-1700010
3.1. Removing the input shaft
3.2. Removing the secondary shaft
3.3. Removing the intermediate shaft
4. Malfunctions and their elimination
5. Assembly of gearboxes 420.3181-1700010-02, 420.3182-1700010
5.1. Assembly
5.2. Requirements
6. Instructions for installing gearboxes 420.3181-1700010-02, 420.3182-1700010 on UAZ vehicles
6.1. Instructions for installing gearbox 420.3181-1700010-02 on UAZ-3160, UAZ-3162 Simbir, UAZ Hunter cars
6.2. Instructions for installing gearbox 420.3182-1700010 on UAZ-3741, UAZ-3962, UAZ-3303, UAZ-2206, UAZ-3909 vehicles
7. Installation kits for gearboxes 420.3182-1700010 produced by Avtodetal-Service OJSC
8. Parts for repair of five-speed gearboxes produced by Avtodetal-Service OJSC
9. List of wear parts of gearboxes
