Removal, disassembly and repair of the VAZ-2107 gearbox

01/26/2022 19,438 VAZ 2107

Author: Ivan Baranov

The gearbox is one of the main components of the chassis of a car. It must always be correctly adjusted and work properly. To carry out self-repair of the gearbox, you need to know how to remove the box on a VAZ 2107. The article provides detailed instructions and a video that describes and shows the process of removing the box, and lists the tools necessary for the work.

Transmission replacement may be required in the following cases:

• its failure;
• when noises appear indicating its malfunction;
• if the gearbox is faulty, the wheels may lock while driving;
• An oil leak also indicates a problem.

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Removing the manual transmission

In any case, in order to repair the VAZ-2107 gearbox, you will need to remove it from the car. And in order to do this, you need to drive the car onto an inspection hole or overpass.

The first step is to remove the rod from the gear shift lever. After this, you need to use a screwdriver to unscrew the screws of the cover that covers the hole in the floor of the car body. At this point, the work inside the cabin is completed; all subsequent removal steps are carried out from below the car.

While under the car you need to:

1. Remove the exhaust pipe;
2. Then the starter is unscrewed and removed from the flywheel housing;
3. The driveshaft is disconnected from the gearbox.

To make it easier to remove the box, you need to disconnect the cross member of the rear engine mount and the speedometer drive cable.

Next, the clutch hydraulic cylinder is disconnected from the gearbox. It is important that when disconnecting the cylinder, you do not accidentally remove the hydraulic hose from it.

After this, you need to unscrew the bolts that secure the clutch housing cover (10 wrench). Next, they begin to directly remove the box, and since its weight is significant, you need to install a reliable support under it.

Then, using a socket wrench, unscrew the bolts that secure the clutch housing to the engine. Now, in order to remove the box, you need to carefully move it back, gradually removing the input shaft from the hub of the clutch driven disc.

This must be done carefully to prevent the driven disk from moving, otherwise it will be difficult to install the box in place. In principle, the removal work has been completed, and the VAZ-2107 gearbox can be repaired.

Also read - Automatic transmission repair, repair features.

Intermediate shaft

Designed to transmit a certain amount of torque from primary to secondary. Rotates on bearings 2, 22 and 19. The gears are integral with the shaft. In the same block, gears of the fifth speed 18 and rear 20 are installed. The latter is installed on a separate shaft 21, connected to the secondary one on splines.

To fill the VAZ 2107 gearbox with oil, there is a special hole 11 on the left side of the housing, which is closed with a plug. The bottom of the case is closed with a steel lid, which is secured with ten nuts. All connections between the lids and the box body are sealed with special gaskets that prevent oil leakage. The bearings of the primary, secondary and intermediate shafts are sealed with seals that prevent oil from leaking out of the transmission pan.

The filling volume of oil for the VAZ 2107 gearbox is approximately 1.6 liters. Some car enthusiasts prefer to fill oil through the top, at the place where the handle is inserted into the gearbox. This method is much simpler than the standard one, since the handle is located in the interior and access to it is not difficult, which cannot be said about the filler hole.

Gear shifting is controlled by a set of forks that are driven by a handle. The structure and main details of the gear shift mechanism are clearly illustrated by the following diagram.

Here numbers 1, 2 and 16 indicate the gear shift forks: third and fourth, first and second, rear and fifth, respectively. Numbers 5, 7 and 9 indicate the rods of the corresponding forks, which are driven by handle 8, located in the interior of the VAZ 2107 car.

The operating diagram of the switching mechanism is as follows: when handle 8 changes its position, its hinge engages with a recess on one of the rods, the other end of which is rigidly coupled to the fork with a bolt 3. The fork, in turn, fits into a groove on the corresponding front gear (16 , 23, 24, 25) or intermediate (20) reverse. Thus, handle 8 ensures the movement of the fork and a certain gear of the secondary shaft is engaged with the corresponding intermediate gear. In this case, the torque transmission chain is closed, the secondary shaft begins to rotate at a speed corresponding to the gear ratio of the gears currently engaged. When the reverse gear is engaged, unlike the others, the handle is “recessed” down when moving.

As you can see, the design of the VAZ 2107 gearbox is quite complex, so it is not recommended to repair it without having the appropriate skills. It is better to entrust this matter to specialists.

Disassembling the box

Increased noise of the gearbox can be caused by wear or failure of its shaft bearings, as well as significant wear of gears and synchronizers. To determine what is causing the increased noise, you will need to disassemble it.

This work is quite complex technologically, and if the car owner is not confident in his abilities, then it is better to contact a specialized service station, otherwise in the future, incorrect assembly can lead to more significant consequences, or to the fact that the gearbox will not work.

But, if you decided to repair the VAZ-2107 gearbox yourself, then this will require a set of keys and sockets, a powerful screwdriver, and pullers for removing bearings.

Operating procedure.

First of all, unscrew the nuts that secure the shift lever housing and remove the lever from the box.

Then the exhaust pipe mounting bracket is removed. After this, the bolts securing the rear and bottom covers of the box are unscrewed. This will be enough to visually determine the condition of the gears and synchronizers.

If significant wear is noticed, then most likely the reason for the increased noise in them. But it is also worth checking the box shafts for axial displacement. If there is one, then the bearings are also very worn and require replacement.

To carry out work to replace worn parts, a complete disassembly of the gearbox will be required. To do this, first remove the back cover by unscrewing the nut securing it, access to which is possible after removing the bottom cover.

To make it easier to remove, you will need to move the 1st-2nd gear slider down. Then, lightly tapping the lid, remove it from the studs.

To gain access to the 5th gear and reverse bearing, you need to press out the plug. After which the 5th and reverse gear block is removed.

Using a puller, the bearing and the secondary shaft oil seal are carefully removed from the cover housing. If they show signs of noticeable wear, they are replaced with new ones.

Signs of the need to replace (repair) the VAZ 2107 gearbox

• Increased noise and vibration in the unit.
• Difficulty shifting or spontaneous gear disengagement.
• Oil leak from gearbox.
• Wheel lock.
• No rotation of the cardan when the gear is engaged and the engine is running.

To eliminate most problems, a complete replacement of the gearbox is not required, but repairs require its removal and installation.

List of required tools

• A set of wrenches (preferably heads with cardan joints) for 10, 13, 19 mm.
• Screwdriver and pliers.
• A long block that can be used to support the box (alternatively, a short strong block and a jack).

Further disassembly

To further disassemble the box, the clutch housing is disconnected from it. This will allow access to the front cover seal of the box. If oil leakage is noticed, the oil seal must be replaced.

Next, unscrew the front cover bearing bolt, the gear block bolt and the intermediate shaft mounting bolt. After which the plate is unscrewed, under which there are springs and slider clamps.

The springs and retainers are also removed, it is important to note which spring was in which socket, since the spring for 5th gear and reverse is slightly longer.

After these procedures, the gear block is removed. But before that, you need to remember the location of the spacer rings. First, the 5th gear gears are removed along with the shift rod. In most cases, gears have travel stops in the form of locking rings; they must be removed carefully.

Then the rear bearing of the intermediate shaft is removed and this shaft is removed from the housing. After this, the slider responsible for engaging 3rd and 4th gears is removed from the body, having previously unscrewed the bolt securing the shift fork from it.

In the same way, the 1st and 2nd gear slider is removed. When removing them, it is important not to lose the locking blocks located in the box housing.

Having finished with the sliders, you can remove the input shaft. The next step is to remove the locking plate, behind which is the secondary shaft bearing.

After removing it, it will be possible to remove the secondary shaft. Disassembly is complete.

Secondary shaft

It is a continuation of the primary in space. It contains gears of the first (23), second (24) and third (25) gears, which move freely and in certain positions engage with the corresponding gears of the intermediate shaft 1. All gears have different diameters, which ensures a change in the amount of transmitted torque .

The secondary shaft rotates on bearings 9, 11 and 12. The first of them is roller, installed in the primary shaft, the rest are pressed into the crankcase and the rear cover, respectively.

Increased noise

After disassembly, you need to troubleshoot the box parts. If severe wear of the gear teeth is noticed, they must be replaced. It is better to replace gears one by one. So as not to confuse the gears.

Many gears have retaining rings. Synchronizers also undergo the same troubleshooting. If they notice even slight wear or damage, they are replaced.

Particular attention should be paid to the condition of the bearings. They should not have any play or the appearance of deep treadmills of balls.

Although, even if the bearing looks good on the outside, it is better to replace it. This eliminates the possibility of noise occurring after the box is assembled.

Spontaneous speed shutdown

If the repair of the VAZ-2107 gearbox is associated with the spontaneous shutdown of any gear, then in this case the sliders and clamps need close attention.

It is necessary to inspect the condition of the fastener seats. If the edges of the seats are heavily worn, then the sliders need to be replaced.

Another method of restoring seats is used by some craftsmen. To do this, a layer of metal is applied to the seats using a welding machine. And then, using a grinder, new seats are cut out in the applied metal.

The method is quite simple, but not very effective, since the applied metal is softer in structure, which means it will wear out much faster.

It is advisable to replace the clamps during repairs, as well as the springs that press them to the slides.

This is done because the springs are constantly pressed and shrink over time, which is why they do not create the required force on the clamps.

VAZ-2107 input shaft bearing: number, price, which one is better to buy, size (5 mortar, 4 mortar)

In the “Classics” manual transmission, the designers provide a radial open single-row ball bearing of class 6 accuracy, which absorbs 90% of radial loads. To select this spare part, you need to pay attention to the radial and axial clearance, ease of rotation, appearance of the product (no corrosion, cracks, nicks, cavities). Before you buy a gearbox input shaft bearing for the “seven”, check out the list of recommended manufacturers. The listed manufacturers produce high-quality products at reasonable prices with exact dimensions in accordance with GOST 520-211.

• Open: 6-50706AU (replaceable without disassembling the gearbox)
• Closed: 6-180502K1US9 (replaceable with disassembling the gearbox)

Table of costs and recommended manufacturers

List of a complete set of gearbox bearings for the VAZ 2107

Bearing size table 6-50706AU

Difficulty switching

The reasons for difficult gear shifting may be severe contamination of the lever linkage or jamming of the sliders.

In order to determine the cause of this malfunction, you need to take the shift lever housing and check if there is any jamming when the lever moves. If there is one, you need to establish the cause and eliminate it.

If the lever in the body moves without much effort, then the reason is in the sliders. After removing them from the gearbox housing, you need to carefully inspect them. Usually, in places where the sliders jam, marks remain in the form of abrasions and scratches.

Then you need to inspect the seats of the slides for the presence of particles that cause jamming. Alternatively, there may be a slight bend in the slider itself. In this case, the slider is replaced.

We are studying the gearbox design to change the input shaft bearing

Before changing the bearing, familiarize yourself with the design of a four-speed gearbox (in a five-speed gearbox, the arrangement of the primary ball bearing is similar). Position No. 4 must be replaced; to do this, you first need to dismantle the gearbox.

• A set of spanners or ratchet heads;
• Two wide flat-head screwdrivers;
• Round nose pliers;
• Hammer, vice, wooden block.

How to remove the gearbox and input shaft bearing on a VAZ 2107

The operation of replacing or dismantling the gearbox is carried out in a pit or on a lift; in exceptional cases, use strong supports with a jack, but this is not safe. Stops are installed under the rear wheels, and the handbrake is engaged with a neutral gear. To make the replacement safe, disconnect the negative terminal from the battery and perform further operations according to the instructions.

1. We remove the cardan from the gearbox and coupling; read how to do this in the article on replacing the VAZ 2107 suspension bearing.
2. Now we dismantle the exhaust (reception) pipe of the manifold; it is held on by three bolts.

1. Find the clutch slave cylinder on the gearbox housing and unscrew it.
2. Next, disconnect the cable with ground, as well as the reverse lights terminal.

1. Now remove the speedometer cable (the so-called speed sensor) and unscrew the lower clutch housing.

1. We unscrew the lower and upper bolts securing the gearbox to the engine with a 19mm wrench.

1. The rear part of the manual transmission is supported by a traverse (swallow), to dismantle the support we unscrew two nuts from the studs.