Gearbox design of the MeMZ-968N power unit of the ZAZ-968M “Zaporozhets”. Synchronizer, gear shift mechanism, speedometer drive, gear shift patterns.

The box housing is made in the form of a block structure and is divided into three compartments by technological partitions. In the first compartment, which is located on the flywheel side, the engineers placed the main gear. The second section of the crankcase houses the first and second gear gears, as well as the reverse gear drive. The third section is for the third and fourth gears. Between the first and second sections there is a technological hole intended for draining oil. This unit also contains a special magnet, thanks to which the smallest metal particles are collected (filtered) from the oil. The third section is connected to the rear cover of the gearbox. There is a hole in it to drain the oil during replacement. Engineers also located the speedometer drive in this section. The clutch assembly is fixed to the front of the crankcase. Replacing the gearbox housing is connected to the bottom of the clutch assembly, so they are replaced at the same time.

Gearbox ZAZ-968M “Zaporozhets”

ZAZ-968M Zaporozhets cars are equipped with a manual 4-speed gearbox.
The drive gears of 1st-4th gears are helical, and the reverse gear has straight teeth, which ensures a smoother ride when moving backwards. The box housing is made in the form of a block structure and is divided into three compartments by technological partitions. In the first compartment, which is located on the flywheel side, the engineers placed the main gear. The second section of the crankcase houses the first and second gear gears, as well as the reverse gear drive. The third section is for the third and fourth gears. Between the first and second sections there is a technological hole intended for draining oil. This unit also contains a special magnet, thanks to which the smallest metal particles are collected (filtered) from the oil. The third section is connected to the rear cover of the gearbox. There is a hole in it to drain the oil during replacement. Engineers also located the speedometer drive in this section. The clutch assembly is fixed to the front of the crankcase. Replacing the gearbox housing is connected to the bottom of the clutch assembly, so they are replaced at the same time.

Engine ZAZ-966

The engine compartment is always overheating due to the poor design of the ZAZ-966V cooling system.
The engine compartment is always overheating due to the poor design of the ZAZ-966V cooling system.

This problem was dealt with in different ways. They extended the “ears”, raised the hood, propping it up as best they could. Personally, I counteracted overheating by correctly adjusting the carburetor and accurately setting the ignition - the 966 was very sensitive to settings. Moreover, in some particularly difficult cases he did not hesitate to slightly slow down the pace of movement.

With 40-horsepower engines, the designers came to their senses. The fan blew cold air to the heated parts.

Technical solutions

The drive shaft is mounted on two bearings, at one end there is a needle bearing, which is pressed into the flywheel, and the other end of the shaft is inserted into the technological hole in the crankcase. A thrust ring is located on the drive shaft to prevent the shaft and bearing from moving out of place.

There are special splines on the front of the drive shaft for the so-called “sliding” fit of the clutch disc. The middle part of the shaft passes through the gearbox. A gear with oblique teeth is installed on the shaft, which is constantly in mesh with the driven gear of the first gear and the reverse mechanism.

The design of the box provides a pair of synchronizers, one for each gear. The synchronizers (crackers) have the same design and overall dimensions, with one difference: in the second and first gears, the reverse gear acts as a clutch.

The outer surface of the hub has splines, thanks to which the synchronizer coupling is able to move. There are also three longitudinal grooves on the hub, which are located at different distances from each other.

Gear shift

Switching speeds occurs due to the movement of three movable drains, couplings and the fork itself. The rods are located in one row and move in special holes, which are located in the rear and middle parts of the gearbox housing. The rods have special grooves into which the switch slide itself fits. In order to fix the working position of the rods, recesses are provided on their planes, which ensure reliable engagement with clamps made in the form of balls.

In order not to engage several gears at the same time, engineers have developed a special locking device, which consists of two locks and a so-called pusher. Gear shifting occurs by acting on a special lever (slide) which is located in a special channel in the floor of the car. The lower part of the lever is connected to the transmission control (selection) mechanism. Also on the rear cover of the gearbox there is a reversing light switch, which is activated (turned on) by a special protrusion mounted on the rod.

DESIGN FEATURES OF THE GEARBOX CONTROL MECHANISM

The gearbox is controlled by lever 1 (Fig. 97) on the body floor tunnel. The lower end of the lever is installed in a stamped housing on a ball joint. The ball part of the lever provides a hinged connection with the slider.

Rice. 97. Gearbox control mechanism: 1 - lever; 2 - retaining ring; 3 - casing; 4 - spring; 5 - thrust cup; 6 - ball cup; 7 - cover; 8 — lock bolt; 9 - shaft; 10—lock washer; 11 - lock nut; 12 - special bolt; 13 — gearbox slider; 14 — washer; 15 - nut; 16 - coupling; 17 — floor tunnel cover; 18 — cover; 19 — support sleeve; 20 — liner; 21 - slider; 22 — guide cup; 23 - damping ring; 24 - ring; 25 - spring; 26 — bracket; 27 — mechanism fastening bolt; 28 — body; 29 — cup fastening bolt; 30 - floor tunnel.

The housing 28 of the mechanism is attached to the tunnel with four bolts 27 and is closed by a cover 7 with a rubber casing 3. The slider rod 21 is connected to the control shaft 9 with an installation bolt 8. The control shaft 9 is connected to the gearbox slider 13 using an elastic rubber coupling 16, which is screwed into the the control shaft 9 is locked with a nut 11. The other end of the coupling 16 is connected to the gearbox slider 13 with a bolt 12.

An indispensable condition for clear and easy engagement of all gears is the reliable tightening of lock bolt 8, nut /5, lock nut II, as well as the location of the lever / control in the neutral position at an angle of 90° to the plane of the body floor tunnel.

ZAZ-968A Zaporozhets: retrotest of the “eared”

Today it is no longer easy to meet a living Zaporozhets. But we were lucky - an excellent copy of the ZAZ-968A fell into our hands.

ZAZ-968A is essentially a deep modernization of the first “eared” Zaporozhets ZAZ-966.

Externally, it can be easily distinguished from its predecessor by a different design of the front end, different turn signals and side lights. But the main family features have been preserved - “ears” - air intakes and stylish round lights. True, the air intakes on the 968 start at the rear axle, while on the 966 they were longer and started in line with the rear arch. The decorative “whalebone” grille disappeared from the front end, which gave way to a decorative chrome element.

No matter what anyone says, from a design point of view, the Zaporozhets turned out to be very nice and harmonious. Many believe that its appearance was completely copied from the 1961 NSU Prinz. However, this is not so - the first running prototypes of our “eared” appeared simultaneously with NSU - in the same 1961. But there is no doubt that the creators of both cars were inspired by the American Chevrolet Corvair.

ZAZ-966 V

ZAZ-966 V
ZAZ-966 V

Seat without backrest

The 966's seat could only be called comfortable. To the envy of the drivers of the “humpbacked” ZAZ-965, under the leatherette of the “eared” seat there was a layer of polyurethane foam. Therefore, the chair looked solid, although there was no solidity in it. The back frame was welded from thin-walled steel tubes, which gradually bent back as they were used. The backrests themselves were not adjustable. To compensate for the increasing tilt over time, planks of different thicknesses were placed under the seat slide. At the same time, the tilt of the pillow inevitably increased. I had to choose a middle ground between not falling back and sliding under the steering wheel.

Warm heart

The MeMZ-968 air-cooled engine with a volume of 1.2 liters develops 41 hp. at 4200 rpm. It is very simple and repairable, and so light that two people are enough to dismantle it.

The power system used a K-126 carburetor and an inertial air filter, which did not require replaceable filter elements. Unfortunately, the Melitopol “air balloon” was not particularly reliable. These engines rarely lasted 100 thousand km - more often than not, half that time. The engine suffered from overheating, as did the fuel pump, which in some situations could simply stop pumping fuel. But what you definitely can’t deny this engine is efficiency. Fuel consumption was around 6 l/100 km at 80 km/h. It’s a paradox, but the next iteration of Zaporozhets - 968M, popularly nicknamed “soap box”, consumed much more - about 10 liters per hundred at the same 80 km/h.

There is no need to talk about any dynamics. In theory, Zaporozhets reaches 100 km/h in 32 seconds. And the maximum speed is 118 km/h. But in practice, by 80 km/h any acceleration ceases. And there is no desire to go faster on the 968.

Mini tractor based on ZAZ gearbox

Happy New Year!

Good evening everyone. I’ve been browsing this forum for a long time, you design interesting self-propelled guns, great. I want to show you my assistant, the iron pony. The very first option was this:

Then I shortened the adapter a little and installed a steering column from a Zhiguli:

Then I shortened it a little more by moving the rotary joint forward:

But three seasons of use in the garden showed that front-wheel drive (especially without differential locking) and an articulated frame are unsuitable in garden beds, so I decided to make a rear-wheel drive tractor. Like this:

brief description of the homemade product:

ZAZ-965 engine in operation, two cylinders (1st and 4th) the other two pistons with connecting rods have been removed. Carburetor VAZ-2101, only the first chamber works. Three pressure springs on the clutch basket were removed (the clutch became softer in operation).

first box ZAZ-965: the differential was removed, the secondary shaft was turned over, a piece was added and it turned out like in the Zhiguli gearbox, the rear exit, then an elastic coupling, a stretched cardan, a Hooke joint (all with MT or URAL):

A single-stage gear intermediate gearbox (homemade z1=17, z2=27) is mounted directly on the first shaft of the second gearbox:

The second ZAZ-968 gearbox works in the opposite direction.
final drives are also self-made gear units (z1=19, z2=53):

continuation, I didn’t fit in the gate a little.

ZAZ rear hub, rear wheels look like UAZ 16, GAZelle disc welded on top of the Zaporozhye one, front wheels together with ZAZ hubs, brakes on all four wheels:

welded frame, square tube 50*50

these photos are fresher

mech. Vintik. Well done, it’s clear that a lot of work has been done. I'm wondering how the ZAZ engine behaves (two cylinders are running)?

, maybe we still need to use a single-cylinder 4-cylinder engine in the future?

first box ZAZ-965: the differential was removed, the secondary shaft was turned over, a piece was added and it turned out like in the Zhiguli gearbox, the rear exit,

Spare parts for manual transmission repair:

economy - from 3,000 to 8,000 rubles. /use, at the request of the car owner, only used parts to reduce the cost of repairs/
business - from 8,000 to 28,000 rubles. /replacement of only directly damaged parts in the unit/
executive - from 28,000 to 60,000 rub. /replacement, regardless of damage, as a set: oil seals, carrier bearings, needle bearings, synchronizers, stoppers, coupling hub locks - plus directly damaged parts/

Our own warehouse of spare parts necessary for the repair of manual transmissions. Bearings, seals, gears, synchronizers, gear couplings, shafts, differentials, manual transmission housings are in stock and on order for all brands of cars.

The photographs below show the disassembly and assembly of the ZAZ Sense 1.3 gearbox. The car owner complained about the characteristic noise of the bearings and the speedometer not working. We change the set of gearbox bearings, oil seals and gearbox speedometer drive:

Photos of disassembly and assembly of another ZAZ Sens gearbox. Also replacing bearings and gearbox seals. But besides this, we additionally change the fifth gear as a set (both gears, synchronizer, fork). The owner did not check the oil level. Only 650 grams of oil were drained from the box.

Features of the gearbox and its maintenance

The Zaz Sens manual transmission was originally designed for Tavria, so it is considered rather weak for a car with a large mass. A number of features can be noted in the design - this is the light pressing of the clutch pedal, which was also characteristic of Lanos, as well as a non-standard gear shift pattern. Fifth gear is engaged by moving the lever backwards, and reverse gear by moving the lever forward. The gearbox mechanism is completely borrowed from Lanos, which ensures clear and easy switching.

Since the box was originally designed for a lighter car, it initially works at the limit, so regular lubricant changes are required. It is recommended to change the transmission fluid every 40-50 thousand kilometers, this will protect parts from premature wear. The best replacement option would be synthetic gear oil that meets the 75w90 standard, quality class GL 4 or 5. High-quality lubrication guarantees no vibration and long-term trouble-free operation.

It is recommended to change the transmission oil at a specialized workshop: with us this service will be inexpensive, and the quality and reliability of the service is guaranteed.

Common box faults

Repair of the ZAZ Sens gearbox may be required due to improper operation and wear of parts caused by design features. Constant operation of the machine under increased load leads to premature destruction of parts. Owners of used cars should pay attention to the following signs of malfunction:

Extraneous noise in the gearbox that disappears when the clutch is disengaged. Noise occurs when the oil level in the box is insufficient, its quality is poor or parts are worn out. Wear of gear teeth over time leads to the inability to change speed while driving, so this alarming symptom cannot be ignored.
Problems with turning on the gear. They turn on with difficulty, you have to make an effort to move the lever. Most often this indicates drive failure, loosening of the lever and other malfunctions of the drive mechanism. To fix the problem, you need to diagnose and replace faulty parts.
Spontaneous transmission shutdown. It occurs due to damaged or worn synchronizers, as well as improper drive adjustment. The problem can only be resolved in a workshop.
The appearance of a crackling sound when changing gears. This problem occurs when the synchronizer ring wears out, bearings and other parts are damaged. It is necessary to carry out diagnostics to determine the exact cause of the crackling noise and eliminate it before serious damage occurs.

We offer inexpensive repairs to the ZAZ Sens manual transmission for these and many other problems. Qualified repairs begin with diagnostics: a specialist will check the box in motion, conduct a professional inspection, dismantling and disassembly, after which a list of all damaged components will be compiled. We offer to buy the required spare parts; the catalog contains new and used parts.

Replacement manual transmission for ZAZ Sens

If the gearbox is significantly damaged, it is not profitable to replace the parts individually - this work will take a lot of time and require large financial costs. We offer to buy a Zaz Sens gearbox assembly and install it in a short time. When a new transmission is sold and professionally installed, it comes with a two-year reliability guarantee and will not require re-repair any time soon. You can also purchase restored gearboxes after a major overhaul: such a purchase will require much lower costs.

We use only original components of excellent quality for replacement. If a used box is installed, it undergoes a preliminary overhaul, this guarantees its long-term trouble-free operation. The warranty card will allow you to fix any repeated problems free of charge.

Why is it worth ordering repairs from us?

Our workshop clients are offered inexpensive manual transmission repairs for any make and model of car; we work with products from the domestic and foreign automotive industry. It is beneficial to use our services for several reasons:

Honest and favorable terms of cooperation. Defects of parts are carried out only in the presence of the client; we do not inflate tariffs and do not deceive customers.
Affordable prices for spare parts and their installation. Take advantage of favorable conditions to solve your car problem at very little cost.
Large selection of components. We always have in stock everything necessary to troubleshoot problems, this will allow you to immediately restore the machine after a breakdown and return it to operation.
Quality and reliability of repairs. The workshop is equipped with new equipment for diagnosing and fixing problems; experienced specialists can handle even the most complex breakdowns.

Call us to make an appointment for repairs in advance and get your car back up and running faster. You don't have to wait in line; we value our customers' time. Take advantage of this great offer to forget about any problems with your gearbox!

The gearbox repair shop is ready to perform the following work:

replacement and repair of ZAZ Sens 1.3 gearbox
replacement and repair of manual transmission ZAZ Sens 1.3
replacement and repair of ZAZ Sens 1.3 gearbox
changing transmission oil ZAZ Sens 1.3
clutch replacement ZAZ Sens 1.3
replacement of the release bearing ZAZ Sens 1.3
replacement of rear oil seal and crankshaft bearing ZAZ Sens 1.3
replacement of the input shaft oil seal and drive seals ZAZ Sens 1.3
replacing the input shaft of the ZAZ Sens 1.3 manual transmission
replacement of the secondary shaft of the ZAZ Sens 1.3 manual transmission
repair of the ZAZ Sens 1.3 gearbox
repair (argon welding) of the ZAZ Sens 1.3 manual transmission housing
repair of the secondary shaft of the ZAZ Sens 1.3 gearbox
replacing the fifth gear of a manual transmission (without removing the gearbox from the car) ZAZ Sens 1.3
repair of 1st and 2nd gears ZAZ Sens 1.3
repair of 3rd and 4th gears ZAZ Sens 1.3
repair of 5th gear ZAZ Sens 1.3
buy gearbox ZAZ Sens 1.3
buy manual transmission ZAZ Sens 1.3
buy ZAZ Sens 1.3 gearbox

Call us to schedule a time for manual transmission diagnostics and repairs at a transmission repair shop. Pre-registration will allow you to find the most convenient solution; we are always ready to meet the client’s wishes.

Our specialized workshops for repairing ZAZ Sens 1.3 manual transmissions provide high-quality service, diagnostics and repair of all types of gearboxes. We offer honest service for your repairs. Your presence is required at all stages of diagnostics and repair of the ZAZ Sens 1.3 gearbox; all work and components are agreed upon. The period for a gearbox overhaul is from 0.5 to 1 working days (subject to the availability of the necessary parts).

We work seven days a week.

We operate a 24-hour consultation line for the repair of manual transmissions (8 965 126 13 83) and delivery for repairs by tow truck (8). A tow truck for manual transmission repairs is provided for a fee (within the Moscow Ring Road - 3000, outside the Moscow Ring Road by agreement).

The cost of work for a major overhaul of the ZAZ Sens 1.3 gearbox is 10,000 rubles (input and output diagnostics, removal and installation of the gearbox, disassembly and reassembly, weekend test drive) + cost of components.

Input diagnostics are carried out with the obligatory presence of the car owner for 30 - 40 minutes after removing the gearbox from the car (inspection, disassembling the manual transmission, washing the internal gearbox housing from metal shavings, dismantling the shafts).

Removal of the gearbox from the vehicle, disassembly and troubleshooting takes place on the day you call for repairs.

Warranty for the repair of the ZAZ Sens 1.3 gearbox from 1 to 12 months or 60,000 km (set individually for each car - depending on the components during repair).