Replacing the clutch cable Lada Kalina 1117 2004 - 2013

Popular domestic model

Lada Kalina is very popular among Russian car enthusiasts, but most of its owners note that the model has a number of significant shortcomings. In particular, criticism is caused by the appearance, comfort and technical equipment of the machine.

Many claims have been made regarding how the Lada Kalina clutch works . Although, reading the instructions for this vehicle, it is difficult to believe that any malfunctions could occur when the clutch operates.

Clutch device

The clutch of this model from AvtoVAZ is single-disk and belongs to the dry subtype. It is equipped with a pressure spring located in the center. The pedal is connected to the clutch disc using a special cable, the length of which is adjusted by a ratchet mechanism. This can be seen if you watch a video demonstrating the design of Kalina.

The lining of the dependent disc wears off and becomes thinner during use. The malfunction is eliminated using a ratcheting mechanism, which compensates for wear by tensioning the cable. The tension causes the release fork to rotate and compress the spring, which is located in the bushing of the control mechanism. The spring, in turn, compresses the clamps located on the toothed tip of the cable. As a result of all these manipulations, the tip is released and the cable is tensioned.

The ratcheting mechanism eliminates the need for car owners to waste time and effort on adjustments. But this is only in the theory developed by Kalina's designers. In reality, when operating a car, you need to know how to adjust the clutch yourself.

Checking the integrity of the clutch cable and plastic clips

The clutch in Kalina is released using a cable drive, one end of which is connected to the pedal and the other to the clutch fork. If the cable or its fastenings are damaged, the connection is broken, the pedal moves freely and pressing it does not lead to an impact on the fork and removal of the driven disk from the flywheel. Accordingly, it becomes impossible to engage any gear or switch between them.

In this case, there are two most likely options: the metal clutch cable has broken or one of the plastic mechanisms with which it is fixed to the clutch pedal on one side or to the clutch fork on the other has broken. The cause can be determined by visual inspection. If it shows that the cable itself is intact, but the lock is destroyed, you may well be able to get to your destination or store on your own, securing the cable in an accessible way.

When adjustment is required

Clutch adjustment is only performed when the engine is switched off. It is required if there is a deviation from the following values:

• full pedal travel does not exceed 146 mm;
• movement of the cable lead relative to the release fork lever - within 270 mm;
• runout of the dependent disc linings does not exceed 0.5 mm;
• the distance between the pads and the rivets that hold them is 0.2 mm or less.

There are several ways to check if your car needs a clutch adjustment.

• You should press the pedal several times in a row and listen for any extraneous noise. If the clutch pedal sticks or squeaks, it is advisable to make an adjustment. In some cases, car owners are unable to visually assess whether the pedal returns to its place freely. In such situations, it is recommended to do the following:

• press the clutch with your hand until it stops;
• stop applying force, but leave your hand on the pedal in order to feel if there is movement.

When is replacement needed?

Of course, the cable will have to be changed in any case when it breaks. But it’s better not to let things get to this point - think about repairs when you notice that the tip has begun to become shaggy. Even a couple of broken wires seriously reduces the strength of the element. You should also consider replacement if the plastic shell wears down significantly.

It should be understood that the clutch cable installed in the Lada Kalina gradually stretches, even if the owner of the car drives it very carefully. Eventually it will become so loose that the driver will one day simply not be able to change gear.

The following signs indicate that there is something wrong with the cable:

• when the clutch is activated, uncharacteristic sounds are heard;
• gears are difficult to shift;
• the pedal fails;
• the clutch does not disengage completely;
• craving weakens.

If you have at least one of the above symptoms, you should think about a technical inspection and then, depending on the circumstances, replacement or adjustment.

The procedure for adjusting the clutch on Kalina

Owners of Lada cars who have discovered faults in their vehicles are interested in how to adjust the clutch. To do this you need to perform a number of steps.

1. Pull the cable forward until it stops at the threaded end. In this case, it is necessary to overcome the resistance of the spring attached to the clutch pedal.
2. While holding the cable, use a caliper to measure the distance from the plastic leash to the clutch release fork lever.
3. By rotating the leash, bring the distance to the required values. Make sure that when releasing the cable, the leash fits tightly to the fork lever.
4. Press the clutch pedal three times to activate the automatic cable length adjustment system.
5. Check the full pedal travel.

Adjusting the clutch on a Kalina car is a procedure that every owner of this car must master. By performing timely adjustments, you can significantly extend the life of your vehicle.

Like all “basins”, Kalina is not at all flawless. Over its more than ten-year history, the model has been refined more than once, but it has not been possible to get rid of some problems. Among the “Kalinovodov” it is recognized that the torque transmission mechanism, due to its design features, is the weak link of the car. Despite all the modernization in this area, car enthusiasts have to periodically adjust the clutch.

Step-by-step replacement of the Lada Kalina clutch cable:

1. First, unscrew the cable securing nut with an “ 8″ wrench. It is located on the clutch pedal inside the car. This is the stop of the cable sheath in the pedal bracket.

unscrew with a key 8

2. There is a locking bracket under the nut. It should be carefully removed using a screwdriver.

Carefully remove the retaining clip

3. Next, you need to remove the body of the mechanism that regulates the length of the cable and pull out the cable by disconnecting it from the pedal mount.

Remove the mechanism housing

4. The cable is located behind the air filter; it should be removed. Pull the clutch lever slightly and pull the cable out.

Pull the clutch lever and pull out the cable

Next, work should be done in the engine compartment. Open the hood.

1.Pull the cable out of the fork mount by pulling it towards you.

2.Unscrew the plastic leash by hand.

Unscrew the plastic leash.

3. The cable end has a rubber cover; you should remove it.

Remove the rubber boot from the cable end

4.Disconnect the end of the cable from the holder on the gearbox.

Disconnect the end of the cable on the gearbox

So, if you have successfully completed the previous steps, it is time to replace the old cable with a new one. All actions should be performed in reverse order, namely:

1. Run the new cable into the hole in the front panel in the car's interior.

Features of the VAZ 2112 clutch

The machine is equipped with a dry-type single-plate friction clutch with a central pressure spring. adjusting the clutch on Kalina any motorist must take into account that the control pedal is connected to the disc via a cable with a special ratcheting mechanism.

How does automatic cable tightening work?

As a result of intensive use, the friction linings of the disc gradually wear out. The ratcheting mechanism built into the drive design allows you to compensate for wear for a certain period of time - it gradually tightens the cable. During operation of the device, the fork rotates and the bushing spring is gradually compressed. As a result, the cable end clamps are compressed, after which the latter is released and tensions the cable.

Troubleshooting Sensor Problems

This mechanism is installed only on the Lada Kalina clutch with an electronic gas pedal. Its function is to control engine modes when changing gears, starting to drive, etc. Sensor malfunctions are reflected on the engine controller as “error 0830”, and the Check Engine lamp lights up. Physically, malfunctions are felt as jerking of the car when changing gears, when the engine is running at low speeds, or a sudden increase or decrease in engine speed when you press the pedal. It is impossible to adjust the clutch sensor on Kalina; it will have to be completely replaced.

This part is located above the pedal, under the steering column. When buying a new one, you should choose sensor 1118-3720015 (for Kalina, Priora, Grants). Replacing it is a little complicated by the inaccessibility of the 2 screws on which it is attached to the pedal bracket.

To remove the sensor, you need to pull the wire block holder out of the hole on the pedal bracket. Then disconnect it from the dashboard wiring harness. Use a screwdriver to remove the spring hook from the holder and unscrew the sensor mount on the pedal bracket (screws).

Without noise and dust: how to properly adjust the clutch on a Kalina station wagon yourself?

You should start working no earlier than the engine has completely cooled down. The setup method is simple and does not require a visit to a car service center, because you can do everything yourself. The step-by-step scheme for completing the work is as follows:

• Before adjusting the clutch drive on Kalina, you should open the engine compartment hood and remove the air filter.
• Visually assess the condition of the cable casing and replace it if damaged.
• Pull the tip toward you until the cable is fully tensioned. After this, check the distance between the fork and the leash with a caliper.
• If the measurements show more than 27 mm, then the distance is corrected by rotating the leader along the thread of the tip.
• Press and release the clutch pedal several times and repeat the measurements.
• If necessary, repeat the adjustment until the required standards are achieved.

Step by step guide

To replace the clutch cable on a Lada Kalina, you need to prepare some spare parts and tools, namely: a new clutch cable, a figure eight wrench, a regular ruler, a rag, a flat screwdriver and a caliper.

1. The first thing to do is to pick up the prepared eight-point wrench and unscrew the nut that secures the cable. You will find it on the clutch pedal in the car. This nut serves as a stop for the cable sheath into the bracket.
2. Using a flathead screwdriver, remove the retaining clip very carefully. It is located directly under the nut.
3. The next step is to remove the housing of the mechanism that regulates the cable, in order to pull out the cable by removing it from its attachment to the pedal.
4. The cable itself is located behind the filter; it needs to be removed. To do this, pull up the clutch lever and calmly pull out the cable.

Now it's time to get to work in the engine compartment of the Lada Kalina.

1. Open the hood and immediately pull out the cable from the fork-shaped fastening, simply pull it towards you.
2. Now we unscrew the plastic leash; you can do this without tools, with your own hands.
3. You will see a rubber cover at the end of the cable; this will also have to be removed.
4. Now you need to disconnect the end of the cable from the holder located on the box

What does incorrect adjustment of the Kalina clutch lead to?

If the gaps are not set correctly, the auto compensator may not work correctly, or may not work at all if the gap under the hood is too low (10mm or less). The release bearing may also howl.

For example, my release bearing was humming in 4th and 5th gears. After adjusting the clutch cable , the noise disappeared. Many questions also arise about the fact that the clutch “takes over” at the very end. This is, in principle, normal. Structurally, the clutch on Kalina begins to grab in the second half of the stroke. Therefore, setting it up to start the stroke means making constructive changes to its operation, which is not desirable.

Work order

Before replacement, Kalina must be installed on a level area. Additionally, its position is secured with a hand brake and under-wheel stoppers.

First, climb into the car interior and unscrew the nut holding the clutch cable sheath bracket to the pedal. This is done with an 8mm wrench.

Next, use a screwdriver to carefully pry the bracket located in the groove of the foot drive finger. It is springy and can fly away in an unknown direction as a result of careless actions, so be careful.

Then remove from the pedal the loop of the mechanism that regulates the length of the cable in automatic mode. Then remove the upper part of the element being replaced from the clutch retainer.

This completes some of the work carried out in the salon. Go to the engine compartment. Here:

• pull the leash out of the clutch fork cavity - just drag it towards you;
• remove it from the cable end by turning counterclockwise;
• remove the rubber protective cover;
• remove the end of the shell from the bracket clamp located on the gearbox.

Now return to Kalina’s salon and first drag the cover onto yourself, and then the cable itself.

Installation

Before installing a new cable, be sure to check the condition of the plastic sleeve attached to the pedal pin. If it is very worn, then replacement is required. When everything is in order, then simply lubricate it with Lithol. The cable on Kalina is installed like this:

• pass it through the hole in the front end (proceed from the interior side);
• install the sealing cover;
• attach the ratchet mechanism to the pedal;
• screw a leash onto the end of the cable (the one with the thread);
• insert the latter into the cut of the clutch fork.

Clutch on Kalina: replacement options

LADA Kalina is a good car, very powerful and durable. And yet, the design of the model has a number of unreliable parts that make themselves felt over time. These include the clutch. In order to identify the malfunction and correctly remove it without the help of others, without calling expensive car repair shops, it is important to know what the mechanism is intended for and how the clutch is replaced on Kalina.

What will tell you about the need for repairs?

Each car has its own “diseases”. A common problem with the LADA Kalina car is that the clutch system does not always work correctly over time. True, this disease is not chronic and occurs quite rarely. This is almost always related to the release bearing or indicates that the clutch disc needs to be replaced . If we consider the top defects of LADA Kalina, then this one confidently takes 8th position. It is not recommended to replace the disc and bearing separately; they are replaced exclusively as an assembly. To avoid having to remove the gearbox every time, it is much better to replace the clutch in one set. Before making a decision about the need to replace the clutch kit, let’s figure out what relevant faults appear and whether it is possible to carry out adjustments, thereby postponing expensive repairs for some time.

The machine itself will “tell” and “show” that tasks have appeared in the operation of the mechanism. The main thing is not to miss the moment and make do with small repairs or adjusting the clutch cable, without waiting for the fault to manifest itself on the highway and the repairs will cost a lot of money.

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Before solving the problem of replacing the clutch, let's look at what can be done in terms of adjustments.

Kalina car is equipped with a single-plate dry clutch with a central spring and connected to the pedal via a clutch cable, which are self-adjusting via a ratchet mechanism.

Malfunctions when the cable needs to be replaced or adjusted:

• the clutch pedal clicks;
• the pedal sticks;
• its stroke is increased;
• the clutch “led”, and only an autopsy will reveal the answer;
• speeds are turned on, but with problems;
• it may slip;
• you can smell the burning smell in the cabin;
• powerful vibration;
• The speeds don't work at all.

In any case, there may be more problems, and the clutch disc will need to be replaced , and with it the entire set. You will have to poke around in the belly of your steel friend.

Traditional first aid methods

If suddenly during a trip you find that the pedal has treacherously failed and there is no longer any hope that the car will survive until the planned trip to the car service center, you need to know 3 probable options for subsequent actions.

1st - ask a friend to hold out the frozen car in tow, 2nd - call a tow truck. But what to do if your friends are far away and there is no tow truck? In this case, there is a 3rd option: try to return the clutch on your own, so that it works until you get to 100.

The driver is required to do the following:

• turn off the engine;
• use the lever to set first gear;
• Immediately after turning the ignition key and starting the engine, press the pedal.

Here we go. Slow? Naturally, but don’t even count on 2nd gear. If you try to switch, the gearbox will instantly fail, and its repair will cost a lot.

Clutch cable selection

Usually, cable is bought on the market, since the cost is cheap and you don’t want to overpay the official dealer for its markup. So, let's take a look at the clutch cable part numbers. An article number was found in VAZ catalogs - 11180-1602210. This is the required part in the assembly.

Causes of malfunction

Decoding the parts of the Kalina clutch cable

There are several circumstances that lead to clutch cable failure. Thanks to the ratcheting mechanism installed on Kalina , you can adjust the length of the cable, which makes it possible to change the tension when the friction part on the disk wears out. But the cable cannot be tensioned forever, and therefore at some point it fails.

Let's look at the main signs of adjusting or replacing the clutch cable on Kalina:

• Missing tension.
• Extraneous sounds when disengaging the clutch.
• The clutch does not disengage completely.
• The pedal falls.
• Gear shifts poorly.

Replacing the clutch cable Lada Kalina 8 cl

Now that we have determined the causes of the defects, we can move on to choosing a cable and the replacement process.