If you increasingly have to hold the gearshift lever while driving, if the transfer case levers have long been tied with ropes :), if when driving, even on the rear axle, a discordant concert begins under you, then it’s time. It's time to remove the box and figure out how this collection of gears and bearings works.
I warn you right away - I’m not going to argue with the authors of books on UAZs, this article is only an addition to the books, taking into account the fact that you don’t have a service station, a lift, three mechanics and the like.
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.
Such design features make it possible to move in reverse. The mechanical type of gearbox has the main advantage of a long service life. A car with such a device copes well with difficulties while driving over rough terrain.
General characteristics
All UAZ gearboxes are similar in design and functioning. Only gearboxes manufactured by Hyundai-Dymos, Korea, differ greatly. These are gearboxes for the UAZ Patriot and UAZ Hunter models of the 452nd and 469th configurations. The company produces five-speed gearboxes, synchronized in all four forward gears.
The boxes produced by Russian manufacturers are unified and can mutually replace each other. In the Russian Federation, the UAZ 469 gearbox is produced by two enterprises. The first is Avtodetal-Service OJSC (ADS), Ulyanovsk and the second is AMZ JSC, Arzamas.
Both companies produce UAZ gearboxes, in Ulyanovsk four-speed with synchronizers in third and fourth gears, four-speed and five-speed with synchronizers in all forward gears. Five-speed, fully synchronized gearboxes are produced in Arzamas.
The fourth supplier and manufacturer of gearboxes for UAZ 469 vehicles is the partner company ADS OJSC, Ulyanovsk, under the EXPERT brand, China. It supplies five-stage, fully synchronized automotive gearboxes to the main conveyor belt of the assembly plant in Ulyanovsk.
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.
Disassembling the gearbox occurs in the following sequence:
- Fixing the machine above the inspection hole.
- Removing transmission oil to reduce unit weight.
- Removing the seats in the cabin.
- Dismantling the speed release fork, clutch pan near the muffler, frame, speedometer shaft and cardan.
- Disconnecting the dispensing system from the main structure, securing it to the side with a rope.
- Removing fasteners.
After this, you can remove the body from the car. The next step is to disassemble the gearbox stages, check all elements of the mechanism for wear, and replace non-functional parts with new ones.
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.
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Disassembly of the five-speed gearbox ADS 420.3181-1700010-02 and 420.3182-1700010 for UAZ is carried out in case of any malfunction during its operation or to replace damaged parts.
The need to disassemble the five-speed gearbox ADS 420.3181-1700010-02 and 420.3182-1700010 for UAZ.
If the reverse gear does not completely disengage when the clutch is depressed, when switching from reverse to forward gear, then the reason is most likely a crack in the reverse fork lever or damage to the synchronizer parts. In this case, all damaged or faulty transmission parts must be replaced.
If the gears in the ADS 420.3181-1700010-02 and 420.3182-1700010 gearboxes do not engage or do not shift sequentially, then most likely the gear shift lever has jumped out of the groove. Self-disengaging gears most often occurs due to a defect caused by excessive wear and deformation of the fork. If the synchronizer ring gear is damaged or worn, it must be replaced with a new one.
Noise or a characteristic knocking sound in the ADS 420.3181-1700010-02 and 420.3182-1700010 gearboxes usually occurs when the driven gears are damaged or broken. Check the gears and replace them. Also remove any remaining metal particles from the crankcase. If a bearing breaks, it must be replaced with a similar one.
If the oil level in the ADS 420.3181-1700010-02 and 420.3182-1700010 gearbox is low, eliminate the cause of the leak and add the specified gear oil. During operation, oil may flow into the transfer case in a volume of up to 325 ml. If oil leaks through the oil seal, the oil seal must be replaced.
Disassembling the ADS 420.3181-1700010-02 and 420.3182-1700010 gearbox for UAZ.
Removing the input shaft.
Remove the input shaft bearing cap bolts, paper gasket and thrust ring. Remove the input shaft bearing cover. Remove the retaining ring.
Remove the input shaft bearing using a bearing puller. Rotate the input shaft until the flat of the shaft matches the gear block and remove the assembly.
Removing the secondary shaft from the transmission housing.
Remove the retaining ring and the output shaft bearing using a special bearing puller. Remove the secondary shaft.
Removing the intermediate shaft of the ADS 420.3181-1700010-02 and 420.3182-1700010 gearbox.
Remove the rear snap ring and countershaft washers. While holding the intermediate shaft journal, remove the fifth gear of the intermediate shaft toward the rear using a tool until the circlips appear.
Pull the intermediate shaft back and remove the outer bearing race from the housing. Remove the intermediate shaft. Further disassembly is carried out as necessary, depending on the needs of maintenance, replacement of parts or repair of components and parts of the ADS 420.3181-1700010-02 and 420.3182-1700010 gearbox.
Transmission diagram
Let's look at an example of a gearbox design diagram and the features of this unit. The engine gearbox housing contains several types of drives, including:
- transmission drive shaft;
- intermediate shafts;
- driven shaft of the UAZ 452 gear shift device.
Bearings serve as supports for these nodes of the transmission. It is worth paying attention to the picture posted here. The diagram on it explains in sufficient detail the structure of the transmission: the front bearings are roller type, and the rear bearing has a double-row ball modification. The driven shaft has a front bearing mounted into the end of the drive shaft. The driven axle is equipped with gears of 1st, 2nd, 3rd gearbox operating modes, and the intermediate one is equipped with gears of 2nd and 3rd gears of the UAZ 452.
As the diagram of the UAZ 452 gear shift device shows, the 1st stage gear has a larger diameter and is located in the rear part of the driven shaft, while the gear from the third mode is the smallest in size, located in the front part of the driven shaft, next to the synchronizer clutch.
In the lower part of the crankcase, where a separate axle is located, reverse gears are installed. The side cover of the gearbox hides inside the crankcase a control device for switching engine operating stages. A gear mechanism is mounted in its rear part to send readings to the speedometer.
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Impressions from the car modernization
After upgrading the car, I drove out onto the road and immediately felt the changes. It should be noted that the tires on the car remained the same from the GAZ-69, size 6.50-16; they were narrower than the UAZ ones and somewhat lighter. Therefore, there was no particular point in using the first speed and I easily started off with the second.
The transmission noise became noticeably lower and the car went 80 km/h very easily. If you squeeze the gas to the floor, the GAZ-69 accelerates to 120 km/h, but there is a fair amount of noise in the cabin. Fuel consumption during quiet driving was up to 15 liters per 100 km.
However, along with the advantages, there were also small disadvantages. For example, the traction when driving in mud disappeared. If I sharply pressed the gas, then almost everything that was there flew out from under the wheels, but it was no longer possible to move under tension, as with the previous engine, because the engine just stalled.
On hard roads, greater engine power and better selection of a 4-speed gearbox made it possible to move much faster.
Even on the road, I began to notice that young soldiers, at the first opportunity, climbed into the second row with a great desire to overtake me from the start at the traffic light. Sometimes I took part in these unofficial competitions and at first, oddly enough, I always got ahead. The old GAZ-69 easily escaped the starting line from the newer UAZ-469.
I was helped in this not only by lighter tires and less weight of the old Kozl, but also by the fact that the military UAZ-469 was equipped with gear axles, and they do not provide advantages when starting from a traffic light.
However, all this happened a long time ago; now the ZMZ-409 engine would not leave a chance for victory. Or maybe put the ZMZ-409 on the GAZ-69 and try again?
Why is it profitable to repair gearboxes with us?
- 20 years of continuous experience of the company, the high qualifications of our mechanics and other specialists have created the basis for the high quality of all work.
- We have modern car service equipment.
- We diagnose and repair UAZ Patriot manual transmissions using professional equipment and tools.
- We ensure affordable repairs thanks to discounts and competitive prices for auto parts and services.
- We have our own spare parts warehouse with a large selection of components.
- We sell spare parts.
- We repair gearboxes urgently - on the day of arrival.
- We provide a quality guarantee for all work performed by us.
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.
Carrying out diagnostics of the UAZ 469 gearbox
The car is subject to diagnostics if its handling has deteriorated. At the same time, squeaking noises may be heard when changing gears. Also, it is necessary to check the condition of the box if the gears activate spontaneously. In some cases, it is necessary to replace bearings and gears to solve the noise problem. If gear shifting is difficult, the synchronizers are checked. The main reason why there is a need to replace the components of the box on an SUV is their natural wear and tear.
One of the signs that the transfer case should be checked is if the grip of the wheels on the road has deteriorated, and noise from its side has begun to increase. Improper use of the vehicle leads to repair of the gearbox on the UAZ 469. In particular, it is necessary to timely change the transmission oil.
Another problem that a UAZ driver may encounter is an oil leak from the gearbox. This manifestation is the result of an increased oil level in the gearbox. Also, if water gets into the system while filling the box with new fuel, the motorist will soon face the problem of fluid leaking from the gearbox. However, it is not only the use of low-quality oil that can cause leakage, since there may be a crack in the crankcase or in the UAZ 469 gearbox cover.
How to turn on the front axle on a UAZ
To transfer torque to the gearbox, a cardan shaft is used, connected to a transfer gearbox that has a pair of stages. Patriot cars use two types of transfer cases: Russian mechanical or Dynamos, which has an electric drive. The latter option has been in use since 2013. In both options, you cannot do without a clutch for engaging the front axle of the UAZ.
The drive is controlled using a lever or washer located on the central tunnel. To turn on or deactivate the UAZ front axle, you need to:
- Fully depress the clutch;
- Move the lever to the desired position (the modes are indicated on the plastic handle). Carry out the operation at a speed of no more than 60 km/h;
- Release the clutch: you can then drive with the axle activated. To disengage it, depress the clutch again and move the control lever to neutral.
Engaging the axle on SUVs with a Dymos gearbox is much simpler: you need to turn the washer to the desired position. The design of the transmission is such that it is not forbidden to connect the axle directly while driving. However, if a reduced speed is required, you will have to stop.
