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.
UAZ checkpoint
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.
everything useful is here
Gearbox Four-speed gearbox with synchronizers in 3rd and 4th gears
1 — clutch release; 2, 6 - primary and secondary shafts; 3 - retaining ring or nut; 4, 10 — front and rear bearings of the secondary shaft; 5 — synchronizer clutch; 7, 8, 9 — gears of III, II and I gears; 11 — retaining ring; 12 — bolt securing the rear bearing of the intermediate shaft; 13 — bearing of the reverse gear block; 14 — axis of the reverse gear block; 15 — reverse gear block; 16 — spacer sleeve; 17, 18 — gears of the 2nd and 3rd gears of the intermediate shaft; 19 — drain plug; 20 - crankcase; 21 — intermediate shaft drive gear; 22 — intermediate shaft bearing; 23 - nut; 24 — intermediate shaft; 25 - plug; 26 — cover of the front bearing of the input shaft.
Four-speed gearbox with synchromesh in all forward gears
1, 16, 23 - primary, secondary and intermediate shafts; 2 — front bearing cover; 3 - special nut or retaining ring; 5 - gasket; 6 — input shaft bearing; 7 — front bearing of the secondary shaft; 8 — crankcase; 9 — synchronizer clutch for 3rd and 4th gears; 10, 11 — gears of III and II gears; 12 — synchronizer clutch for 1st and 2nd gears; 13 - 1st gear gear; 14 — locking plates; 15 — bearing; 17 — retaining ring; 18 — washer; 19 — spacer ring; 20 — intermediate shaft bearing; 21 - special bolt; 22 — special washer; 24 — reverse gear axis; 25 — reverse intermediate gear; 26 — drain plug; 27 — gear block for driving the intermediate shaft and 3rd gear; 28 — retaining ring; 29 - plug; 30 - roller bearing.
Five-speed gearbox
1 - input shaft; 2 — bearing cover; 3 — cuff of the input shaft; 4 - retaining ring; 5 — ball bearing of the input shaft; 6 — roller bearing of the secondary shaft; 7 — splined crown of the input shaft; 8 — blocking ring; 9 — synchronizer clutch for 3rd-4th gears; 10 — coupling hub; 11 - key; 12 — splined ring of the 3rd gear gear; 13 — third gear gear; 14 — gear bushing; 15 - 2nd gear gear; 16 - crankcase; 17 — 2nd gear bushing; 18 — splined ring gear of the 2nd gear; 19 — synchronizer clutch for 2nd-1st gears; 20 — splined ring of the 1st gear gear; 21 — 1st gear gear; 22 — bushing of the 1st gear gear; 23 — roller bearing of the secondary shaft; 24 — secondary shaft bushing; 25 — fifth gear driven gear; 26 — 5th gear housing; 27 — double-row ball bearing of the secondary shaft; 28 — spline washer; 29 — retaining ring; 30 - secondary shaft; 31 - bolt; 32 — disc spring; 33 - support ring; 34 — drive gear of 5th gear; 35 — splined ring of the 5th gear drive gear; 36 — synchronizer spring; 37 — synchronizer block; 38 — 5th gear synchronizer clutch; 39 — ball bearing of the intermediate shaft; 40 — roller bearing of the reverse gear; 41 — reverse gear; 42 — reverse gear axis; 43 — gear block for driving the intermediate shaft and 3rd gear; 44 — intermediate shaft; 45 — roller bearing of the intermediate shaft; 46 — bearing cover.
UAZ vehicles are equipped with three types of mechanical three-shaft gearboxes:
— four-speed, with synchronizers only in 3rd and 4th gears; — four-speed, with synchronizers in all forward gears; — five-speed, with synchronizers in all forward gears.
Four-speed gearboxes are interchangeable, but may have different sizes of input shaft splines (for different clutch drive discs). Five- and four-speed gearboxes are interchangeable complete with their transfer cases and driveshafts. When installing a five-speed gearbox instead of a four-speed gearbox, it is also necessary to modify the body floor hole for the transfer case levers. The components and parts of different gearboxes are not interchangeable.
The four-speed, partially synchronized gearbox consists of a one-piece cast-iron crankcase in which the primary, secondary and intermediate shafts are mounted on ball bearings. The front end of the secondary shaft rests on a roller full complement bearing in the bore of the rear end of the primary shaft, and the rear end rests on a double-row ball bearing, along which the gearbox and transfer case are centered.
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.
Engines installed on GAZ-69
Soon the UAZ-469B car went into production, and since Since the new car was much more dynamic and comfortable than previous models, most GAZ-69 owners began installing UAZ and Volgov engines in their cars.
However, among the adherents of more powerful engines, there were also those who were partial to the engine from the UAZ-450. Due to the fact that it had a piston with a diameter of 88 mm, the engine power reached 62 hp.
I somehow came across such a cylinder block, but pistons and rings for it were in real short supply at that time and I was unable to find them. I must say that the only time I accidentally saw such a rare engine assembled in scrap metal. After such a meeting, I became a little interested in restorers of old equipment, because they find exclusive parts somewhere.
There was another engine in the USSR that was chased by Kozlikov lovers and which was valued much higher among foresters and hunters than the Volgovsky. It was a Polish engine from a Nysa car.
In its pedigree, this engine had roots from the GAZ M-20 engine, but was modernized by the Poles while maintaining the old dimension and converted into an overhead valve. With an engine power of 70 hp, it pulled like crazy at the bottom and when driving tight, it had absolutely no competitors.
Based on the above, the real contender for me for installation on the GAZ-69 car was the Volgovsky engine from the GAZ-21. However, preparations for the operation to install another engine took time and in my case took a lot of time.
Around the same time, I came across an interesting article about the modernization of production processes and it concluded that it makes no sense to separately reconstruct one workshop in production, because this will not lead to an increase in output throughout the enterprise.
After reading this and thinking a little, it became clear to me that if in my case I installed a more powerful engine, then I would also need to install a gearbox and transmission from a UAZ. Only then will I receive maximum benefit from the planned refurbishment. To put it simply, after the conversion I will have a modern UAZ in the skin of the GAZ-69.
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.
Malfunctions and repairs
The first signs indicating a malfunction of the automotive system should force the car owner to carry out diagnostics. In some cases, this can be done on your own. Simple breakdowns can be repaired with your own hands. It is better to entrust more complex faults to a service center.
Signs indicating the need to repair the UAZ gearbox:
- deterioration of management;
- squeaks and extraneous noises when changing speeds;
- independent activation of transmission.
In most cases, when uncharacteristic noise is observed, the cause lies in wear or defect of the bearings and gears. Stiff gear shifting indicates a malfunction of the synchronizers.
The main reason for the problems that arise is the natural wear and tear of parts.
The need to check the transfer case is indicated by deterioration in wheel adhesion to the road surface and increased noise levels from the area where the unit is located. Damage is caused by: careless operation of vehicles, untimely maintenance, use of low-quality consumables, fuel and gear oil, lack of control over the volume of working fluids.
Another group of problems is related to the leakage of the oil mixture from the gearbox. Possible reasons:
- exceeding the maximum oil volume in the box;
- water entering the system when refueling;
- a crack on the unit cover or on the crankcase.
The UAZ high-speed gearbox consists of a large number of working elements and components. Their normal functioning and interaction ensure reliable use of vehicles. Gearbox repairs will not be required if you regularly inspect your vehicle.
Mechanism adjustment
After assembling and installing the new switching mechanism, it is necessary to adjust the rods and the entire system. The goal is achieved by changing the length of the vertical and horizontal rods. Do-it-yourself setup sequence:
- Move the gear shift lever to the neutral position, and move the element responsible for selecting the gear all the way.
- Move lever 1 to positions corresponding to speeds 1 and 2. While checking that the elements are not pulled up, connect and secure the selection rod.
- Similar actions must be carried out for other gear stages.
After work, you should check that the gears are fully engaged by starting first gear and reverse. The lever must not come into contact with other parts or controls. The optimal gap size is up to 3 mm.
How to disassemble
Before repairing a 5- or 4-speed gearbox (new model), you must carefully study the device diagram, prepare material and tools. To dismantle the unit yourself you will need:
- wrenches: open-end and socket;
- screwdrivers;
- hammer;
- assembly shovel.
The large weight of the product due to contact with the dispensing system requires an assistant during operation and removal of the box.
How to assemble
Assembly and installation of the automatic transmission is carried out in the following order:
- Placing the box in place, tightening the bolts and other fasteners.
- Attachment to the main structure of the transfer case.
- Installation of the speed release fork, clutch pan near the muffler, frame, speedometer shaft and cardan. At this stage you can assemble the lever.
- Installation of seats in the interior.
- Filling the container with new transmission oil.
After this, you can remove the car from the inspection hole. To install a new gearbox on a UAZ and replace other parts, first carefully read the mechanism diagram.
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.
Design and principle of operation
The gearbox diagram contains information about the main and additional elements of the system. The UAZ gearbox structure includes the following units and parts:
- Fully synchronized installation, ensuring speed equalization and smooth switching.
- Primary shaft on 2 supports.
- Helical intermediate gears for shaft drive.
- An angular contact ball bearing, consisting of 2 rows and located on the rear of the shaft, is necessary to perceive and respond in a timely manner to loads arising during driving in the radial and axial planes.
- A transfer case consisting of a main axle shaft and a gear with a large working life.
Conversion of GAZ-69
After some time, a breakdown occurred and I did not patch Trishkin’s caftan, but pulled out the engine, gearbox and transfer case at once.
I started the re-equipment with the installation of a Volgov engine. I secured it with the rear part to the engine cross member, and welded brackets to the frame under the front part using pre-prepared plates.
In order to dock the gearbox with the RK, I had to unscrew the body and raise it by 200 mm.
Having secured the gearbox with the transfer case, I began to manufacture the rear brackets for the transfer case support, and when I secured the transfer case, I removed the rear engine mounts from the yoke.
The time had come to cut out in the body what was preventing it from being put in place, so that in the future, to remove the gearbox and gearbox, you wouldn’t have to remove it again.
When the body was installed, the intermediate axis of the clutch drive had to be shortened and welded again, because it was impossible to put it in place, because it did not fit between the frame and the flywheel housing.
Next, it was the turn of the driveshaft. I couldn’t find the original rear universal joint, so I had to solve the problem using a makeshift method. I took two cardan shafts with the condition that one of them had a normal working splined part. I measured the distance between the flanges of the bridge and the transfer case, and then cut them with this calculation, as it turned out, almost in half.
Then, he took two corners of the thirty and clamped these remains of the cardans with the corners in a vice. The corners acted as centers for me. Then, he placed two electrodes on the cardan forks and aligned the cardan shafts so that they were in the same plane.
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About the book: Manual of the ADS EXPERT gearbox for UAZ. 2007 edition. Book format: pdf file in zip archive Pages: 19 Language: Russian Size: 6.9 mb Download: free, without restrictions and passwords
Manual for the five-speed ADS EXPERT gearbox for UAZ, installation, malfunctions and their elimination.
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:
Transmission 420.3181-1700010-02 is designed for installation on passenger cars of the UAZ-3160, UAZ-3162 Simbir, UAZ Hunter families with gasoline engines ZMZ-409, UMZ-4218 and diesel engines ZMZ-514 and Andoria.
Gearbox 420.3182-1700010 is intended for installation on vehicles of the UAZ-3741, UAZ-3962, UAZ-3303, UAZ-2206, UAZ-3909 utility vehicles 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 transfer case has been modified, a bracket for mounting 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 on the lever, which eliminated the possibility of transmission oil 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 consumption by up to 20%. — Installation of the gearbox is possible with either a spur or helical 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 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
Source
Operating principle
In order to understand and imagine how the process of changing the speed modes of the engine and the corresponding indicator of the permissible speed occurs, let us turn to a short explanation. The lower stages, which ensure the vehicle starts, are activated by the most powerful gear, which moves along special skids located on the driven shaft. This action allows you to transfer enough force to a heavy car for the car to start moving.
As soon as the car starts moving, you can switch to second gear, due to which the car does not stop and its movement is not very fast. However, the second speed stage will not be enough if you need to reach a speed of about 40-50 km/h. In this case, higher gears will be required.
As for the 3 and 4 speed modes and the corresponding gears, which provide a high number of revolutions per second, they are controlled by a synchronizer clutch. Some modifications of the gearbox on the UAZ 452 were produced, where the switching of 1st and 2nd speed modes of the transmission was also carried out using an additional synchronizer clutch. However, in this case we are considering a transmission option with one synchronizer clutch.
Operating principle
In order to understand and imagine how the process of changing the speed modes of the engine and the corresponding indicator of the permissible speed occurs, let us turn to a short explanation. The lower stages, which ensure the vehicle starts, are activated by the most powerful gear, which moves along special skids located on the driven shaft. This action allows you to transfer enough force to a heavy car for the car to start moving.
As soon as the car starts moving, you can switch to second gear, due to which the car does not stop and its movement is not very fast. However, the second speed stage will not be enough if you need to reach a speed of about 40-50 km/h. In this case, higher gears will be required.
As for the 3 and 4 speed modes and the corresponding gears, which provide a high number of revolutions per second, they are controlled by a synchronizer clutch. Some modifications of the gearbox on the UAZ 452 were produced, where the switching of 1st and 2nd speed modes of the transmission was also carried out using an additional synchronizer clutch. However, in this case we are considering a transmission option with one synchronizer clutch.
The UAZ gearbox has a synchronizer, which is designed to smoothly switch on modes by equalizing the rotation speeds between the intermediate and driven shafts. This feature of the device not only provides more comfortable driving, but also protects the leading clutch mechanisms from damage and rapid wear.
Tuning the GAZ M-20 engine
When I returned from the army, I tried to boost the original GAZ-69 engine and to do this I milled the cylinder head so that the valves did not rest against it.
I also pressed out the exhaust valve guides and sharpened them to accommodate the thicker valve stem from the PAZ engine. Next, I drilled the sockets and ground the valves.
They installed PAZ exhaust valves because they had a sodium filler and did not burn even with 76 gasoline. However, the problem was that finding them was extremely difficult.
After carrying out the work described above, the valves stopped burning, and the engine noticeably increased in traction and on a straight road could accelerate the car to 110 km/h. My tuned engine lasted about 15 thousand km, after which water started to flow into the sump.
An autopsy showed that the engine block from the exhaust valve to the cylinder liner had burst and could no longer be repaired. Unfortunately I no longer remember the cylinder number. This experiment forever discouraged me from boosting engines.
True, I once put a triple shaft into a cheap engine, but there were special factory connecting rods and this Zhiguli engine ran without any complaints.
Gearbox slide: what it is, signs of wear, how to adjust it yourself
Not all car owners know the name of this or that part in their car. In this case, we are talking not only about the mechanisms “hidden” in the engine, but also about the devices with which they interact literally every day. One of these parts is the gear shift lever.
Note: The name "rocker" is not the official name for this mechanism, but it is generally accepted. In fact, this part is called the transmission control drive link.
Signs of gearbox wear
The driver must pay attention to possible malfunctions of vehicle components, including knowing the characteristic signs of wear on the gear shift gate, in order to take timely measures to replace it. Despite the fact that the mechanism is quite reliable, you should be aware of the following “symptoms” of its imminent breakdown:
