Manual for a five-speed gearbox ADS EXPERT for UAZ, installation, malfunctions and their elimination. Gearbox: the right choice for UAZ UAZ 5-speed gearbox diagram

Gearbox UAZ

many owners domestic cars often encounter malfunctions in the gearbox on the UAZ. But the Russian person is arranged in such a way that he always prefers to postpone repairs until later. As a result, the UAZ gearbox lever often starts to act up.

The rumble of gears is constantly heard from the transmission, and sometimes the box stops responding altogether. It's time to start repairing it or replacing it with a more advanced one, for example, an ADS checkpoint or a Daimos checkpoint.

Five-speed gearbox for UAZ Patriot

The Russian organization Avtodetal-Service (ADS) specializes in the production of gearboxes for UAZ vehicles. The 5-speed gearbox "ADS Expert" is supplied to the Ulyanovsk Automobile Plant, where it is equipped with current models of domestic SUVs. It is a one-piece crankcase and is synchronized in all forward gears.

The gearbox is equipped with both a spur and helical transfer case. Modern boxes "ADS Expert" have the following features.

1. By increasing the length of the gear shift lever, the gearbox mechanisms function more smoothly.
2. The redesigned transfer case stem is equipped with a handbrake return spring mounting bracket, making it much easier to assemble the gearbox during installation.
3. The general layout of the gearbox and the selective gear change device have changed somewhat. This made it possible to prevent oil leakage and protect the gearbox casing from the penetration of earth and water.
4. A special sensor is built into the design, which provides uninterrupted power to the rear lights.
5. The transmission chamber filling port is 2 cm lower. This is done to improve the circulation of oil inside the gearbox. Its entry into the transfer case is completely excluded.

In addition to ADS Expert, in 2013 an improved version of the gearbox from Daimos was developed for the UAZ Patriot, based on electric control. This made it possible to completely eliminate the use of the RCP lever. Instead, a special washer is built in. The rear has also changed. cardan shaft: it was shortened and the intermediate support was removed.

Gearbox repair

The 5-speed Daimos gearbox is also suitable for other UAZ models, including Simbir, Hunter and UAZ-3160.

To install a new type of gearbox on the UAZ Hunter, it will be necessary to change the floor hatches of the car body to more modern ones. The remaining 2 car models will require a little modernization, since it is necessary to cut a hole in the floor for the gearshift lever.

When conducting installation work qualified assistance will be needed, therefore it is recommended to entrust the replacement of the gearbox to a licensed service station.

If you want to replace some parts of the gearbox yourself, use the instructions for complete disassembly and assembly of the gearbox on the UAZ. In this case, the repair can be carried out without the use of a lift and third-party assistance.

Necessary tools and preparatory work

Dismantling the UAZ gearbox will require the following tools and materials:

• a set of open-end and socket wrenches ranging in size from 10 to 36;
• a special wrench for tightening flattened nuts (you can use a bicycle wrench);
• a set of Phillips and flat screwdrivers;
• service key with a straight and curved end (pliers);
• copper synchronizer or rod for working with gears;
• a small piece of metal pipe for holding keys when screwing nuts in hard-to-reach places;
• chisel core and heavy hammer;
• set of gaskets for UAZ gearbox;
• quality sealant to be used to install gaskets.

When choosing a set of keys, it is important that they are as compact and thin as possible. Most fasteners are in an inconvenient position for dismantling, so choosing the right wrenches will save you time and nerves.

It is advisable to take gaskets for the current model, but if your car is an old model, for example, with a UAZ 3303 gearbox, any set for the previous generation of cars will do.

If there is a need to upgrade the gearbox, you will need to buy special sets of hardware for the gearbox and transfer case. The second set can be problematic as it is not easy to find in auto parts stores.

The UAZ gearbox scheme has its own characteristics for connecting the transfer case and gearbox. Of course, this type of construction provides a huge advantage, but it is difficult to remove it yourself, since the assembly weighs about 80 kg. Without outside help, you will have to raise the car with a manual winch. At the same time, you need to make sure that she has a reliable support. For example, a metal frame or a solid beam ceiling. The design should easily support the weight of your vehicle.

Before starting work, you need to install the machine on a uniform surface. Then it is necessary to drain the oil from the gearbox and transfer case. Despite the common supply system, each of them has separate drain plugs. While the grease flows out, you can dismantle the front seats, dashboard and 2 hatches, which are located at the bottom of the body. After the oil drains to the end, you need to return the plugs to their place.

Dismantling of the assembly connecting the checkpoint and razdatka

Disassembled box UAZ

Start by unscrewing the crossbar of the frame, which is located under the handbrake system. Dismantle the front cardan by disconnecting it from the transfer case flanges. Disabling the front axle couplings will help facilitate this process. The rear cardan must be removed from the upper side of the body.

The clutch system must be dismantled, you should start by unscrewing the fasteners of the splines of the input shaft, while the hose is pushed into the bell. Unscrew the 4 bolts that hold the clutch fork cover and remove the spring. Then unscrew the functional cylinder controller and pull out the plug.

The transfer case and gearbox will need to be well wrapped with a cable or rope and left for a while. Unscrew the cushion mounts and hardware holding the gearbox to the bell. This is done gradually and evenly. It is possible to completely unscrew the bolts and nuts only if the box has slightly moved away from the bell. It is recommended to make a temporary support for the motor of the machine using a jack, otherwise its lower part will hang and interfere. After successfully disconnecting the gearbox, you can completely remove it.

Worn parts inside the bell are best replaced with new ones. This is especially true for studs, as their threads grind off very quickly.

How to start dismantling the gearbox

Remove the handbrake lever so that it does not interfere. After that, unwind the hardware connecting the gearbox and transfer case. Most often, this cannot be done in one motion, since the parts are held together with a sealant. You will have to hit the knot hard to separate them. It is very important to keep track of spare parts, after disconnection nothing should be lost. It is advisable to place them in one container and set aside until assembly.

The gearbox and transfer case should be inspected for worn parts. To disassemble these parts, you need to try hard, because the bolts and nuts are in hard to reach places.

The input shaft has a roller bearing that does not have a race, so in most cases it crumbles when dismantled. After assembling it, you need to pay attention to how the last video is placed. If the roller enters easily, it will have to be changed, as this indicates wear on the part.

OAO "Arzamas Machine-Building Plant" is the city-forming enterprise of Arzamas and one of the largest enterprises in the Nizhny Novgorod industry. It was founded in 1972 as the Arzamas Automobile Spare Parts Plant of the Gorky Automobile Production Association. For 35 years of its activity, the plant has become the leading enterprise in the Russian Federation for the production of wheeled armored vehicles. Today it is a plant specializing in the production of armored personnel carriers BTR-80, BTR-80A, BTR-80K, BREM-K, UNSH, modernized BTR-60PBM, BTR-70M, BRDM-2A, special vehicles "Vodnik", " Tiger", as well as for the manufacture of parts and assemblies for cars manufactured by GAZ OJSC. It is part of the GAZ Group holding.

Manual five-speed gearbox 31606-1700010 for UAZ cars has a peculiar gearshift algorithm. The back is where the second should be. And the fourth is in place of the back. The idea of ​​placing reverse gear opposite the first one is not so bad: it will greatly help the driver trying to get out of the "ambush" in a roll. The inclusion of reverse gear - without "foolproof", without blocking. Changing the gear shifting order takes some getting used to.

Previously, for UAZ vehicles, the choice of gearboxes is reduced to two four-speed versions. The first has only third and fourth gears synchronized and more "cargo" selection gear ratios, higher reliability due to fewer parts, the design allows you to disassemble and assemble the mechanism in the field. Shifting gears requires a double clutch release. The second four-speed gearbox, which appeared in 1989 and was produced in parallel with the first, is synchronized in all gears. These gearboxes differ as follows - for an unsynchronized box, the lever stroke when the first gear is engaged is twice as long as for the other stages. In synchronized gear, all gears are "equal".

Five-speed gearboxes began to appear on UAZ vehicles produced already in our century. One comes from Ulyanovsk and the second from Arzamas. The checkpoint from Arzamas promised to be more reliable than the Ulyanovsk "five-speed" with an attached fifth gear crankcase. But a peculiar gearshift algorithm confuses drivers with an unusual logic of work. Yes, and reviews about the reliability of the checkpoint from Arzamas (or just ArKPP) are not the most pleasant. At the specialized forum "Uazbuka" a lot of useful tips and stories about ArKPP.

Subsequently, 5-speed gearboxes "Dymos" from Korea began to be installed on UAZ vehicles, and 5-speed gearboxes from Avtodetal-Service OJSC appeared in various modifications.

About the book: ADS EXPERT gearbox manual for UAZ. Edition 2007.
Book format: pdf file in zip archive
Pages: 19
Language: Russian
The size: 6.9 mb
Download: free, without restrictions and passwords

Five-speed gearbox ADS EXPERT, manufactured by JSC Avtodetal-Service, mechanical, synchronized in all forward gears, in a solid crankcase 420.3181-1700010-02 or 420.3182-1700010. The gearshift scheme is classic.

Application of the five-speed gearbox ADS EXPERT:

Gearbox 420.3181-1700010-02 is designed for installation on cars families UAZ-3160, UAZ-3162 Simbir, with gasoline engines ZMZ-409, UMZ-4218 and diesel engines ZMZ-514 and Andoria.

Gearbox 420.3182-1700010 is designed for installation on vehicles of the UAZ-3741, UAZ-3962, UAZ-3303, UAZ-3909 family with gasoline engines UMZ-4178, UMZ-4218, UMZ-4213, ZMZ-409.

In order to increase the resource indicators of the five-speed gearbox ADS EXPERT, its modernization was carried out:

1. Increased the length of the gear lever in the gearbox mechanism. The design of the lever return cam to the neutral position has been changed, which made gear shifting more clear and easy, and eliminated the possibility of self-deactivation of forward and reversing.

2. The stud for the gearbox has been improved, the parking brake return spring mounting bracket has been additionally installed, and the design of the gearbox rear end lug crankcase has been changed, which increased convenience and saved time when installing and assembling the gearbox with the transfer case.

3. The design of the selective gear shift mechanism has been changed, an additional rubber seal of the lever has been introduced, which made it possible to exclude the possibility of a transmission leak from under the lever. The properties of the rubber from which the anther is made have been improved, which provided complete protection of the gearbox mechanism from dust and dirt and significantly increased the resource of the anther, and as a result, its reliability.

4. A reinforced reverse gear sensor with protection against aggressive environment, it ensures its trouble-free operation.

5. The filler hole in the gearbox housing was moved 20 mm lower, an oil deflector for the output 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 five-speed gearbox ADS EXPERT has a number of consumer advantages:

- Extended speed range.
- Reduced fuel up to 20%.
- The installation of the gearbox is possible both with and with the transfer case.
— Reducing the noise level during operation of the gearbox up to 80 dB.
— Easy and precise gear shifting.
— Wide range of installation kits.

Contents of the manual for the five-speed gearbox ADS EXPERT for UAZ vehicles.

1. General information about gearboxes 420.3181-1700010-02 and 420.3182-1700010

2. Operational, specifications 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 the gearbox 420.3181-1700010-02 for cars UAZ-3160, UAZ-3162 Simbir, UAZ Hunter
6.2. Instructions for installing gearbox 420.3182-1700010 for UAZ-3741, UAZ-3962, UAZ-3303, UAZ-2206, UAZ-3909 vehicles

7. Installation kits for gearboxes 420.3182-1700010 manufactured by Avtodetal-Service JSC

8. Parts for the repair of five-speed gearboxes manufactured by JSC Avtodetal-Service

9. List of wear parts for gearboxes

UAZ cars (loaf) have the most spacious body. The body of the machine is made of durable material. The vehicle is equipped with security systems, durable power unit, which is capable of developing a power of more than 100 Horse power, transmission system.

All-wheel drive cargo-passenger UAZ, which has cross-country ability, began to be mass-produced at the Ulyanovsk Automobile Plant in the mid-1960s.

UAZ transmission components

On cars of the UAZ - 452 family of a new sample, there is manual transmission(four-stage). Inertial-type synchronizers provide easy gear shifting. The five-speed ADS gearbox is synchronized in all forward gears.

UAZ can be equipped with a 5-speed manual transmission Daimos (DYMOS). This gearbox is known for its reliability. The average resource of its work is 300,000 km. Filler plug located in the middle of the box, draining from below. They can be unscrewed with a hex wrench. When oil is drained, special containers should be prepared. New fluid must be filled up to the level of the oil filler hole on the box. The dipstick allows you to accurately determine to what mark the liquid is filled. An alternative to the probe can be a long nail. For preventive purposes, every 15,000 km it is necessary to measure the oil level.

The presence of mechanics on this option vehicle fully justified. It is important to use such a machine on rough terrain, off-road. In addition to this, there will be no problems with towing.

The gearbox has external shift levers. The lever in the cab moves freely both parallel and perpendicular to its axis.

The machine is equipped with a transfer case. In the design of the transfer case on the UAZ 452: drive axle shafts, gears. All listed components are in a cast-iron crankcase. The crankcase and cover are connected with nuts. The shift fork rods are securely fixed in the cover.

There is a slot, bearings. There is a helical gear for the speedometer drive. An intermediate shaft is fixed on the "loaf" bearings. This box has reliable gears with straight teeth.

Thus, the checkpoint on the UAZ 452 consists of many components and assemblies. This unit needs regular maintenance.

The need to diagnose the gearbox UAZ model 452

This vehicle must be diagnosed if control began to deteriorate, characteristic creaks began to be heard when gears were changed or gears began to change spontaneously. Transfer case UAZ should be checked if the grip of the wheels with the road has noticeably worsened, a rumble began to appear, an increasing noise during its operation.

During the passage of maintenance, the masters must check the system for oil leaks, the level of lubrication. All worn parts in the transmission system must be replaced with new ones. Also, diagnostics involves lubricating the axis of the levers, adjusting the front links.

Scheduled diagnostics in a professional auto repair shop allows you to accurately determine the existing nature of the problem with the box, eliminate existing problems at an early stage.

Causes of breakdowns

As a rule, the need to replace the main components at the gearbox arises with 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 a gearbox on a UAZ, high-quality oil should be used. If the liquid does not have the proper quality, then characteristic noises from the side of the box may occur due to this. When the synchronizer or its parts are worn out, it is always difficult to change gears. Pay attention to the details of the switching mechanism. When the gear teeth are deformed, self-disengagement of gears is often noted.

Gearbox removal process

Repair of a checkpoint on a UAZ 452 is quite possible to do it yourself. This requires:

• a set of wrenches, including the wrenches needed to tighten the nuts;
• screwdrivers;
• a hammer;
• chisel;
• pliers.

Dismantling algorithm.

The car must be 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, gear levers from the boxes are removed.

The speedometer shaft, suspension mounts in the undercarriage, levers are subject to removal brake system. As a result, an exit to the clutch housing opens. A box is fixed on it with fastening nuts, which must be unscrewed, then the UAZ gearbox is carefully extended along with the transfer gearbox until the splined shaft exits the flywheel. The driver will need an assistant to remove the box.

The assembly of the UAZ gearbox requires due attention. With self-assembly, the driver may have difficulty installing the input shaft in the clutch system. With this process, it is necessary to actively move the box so that the shaft gets into the splines.

As soon as the disassembly into individual component parts has taken place, the box must be washed in kerosene and dried. All component parts are checked for integrity. First of all, this concerns the crankcase, shafts. If the threads on the shafts are damaged, they must be replaced. It seems dangerous to operate the machine if the gears are chipped.

Thus, the timely repair of the UAZ "loaf" checkpoint helps to extend the life of the box.

4. Turn away bolts of fastening and remove a case 15 of the fifth transfer with the back bearing 19 of a secondary shaft.

5. Unscrew the bolt 24 for fastening the rear bearing of the intermediate shaft (the bolt has a left-hand thread) and remove the Belleville spring 27 and thrust washer 28.

6. Remove fifth gear 30 with needle bearing 23 and blocking ring 31 from the intermediate shaft.

7. Turn out a lock bolt 31 (see. rice. 189) of the fifth gear fork and remove the clutch 32 (see rice. 186) with a fork. At the same time, hold crackers, balls and synchronizer springs.

8. Using a puller, remove the roller bearing 13 (without the inner ring) with the thrust ring 14, the spacer sleeve 16 and the driven gear 17 of the fifth gear from the secondary shaft.

9. Using a puller, remove the hub 25 of the fifth gear synchronizer with the thrust washer 29 from the intermediate shaft.

10. Turn away bolts of fastening and remove a forward cover 2. Then remove a lock ring 47 of the input shaft bearing.

11. Remove the covers 45 and 36 of the intermediate shaft bearings.

12. Using the threaded hole M8 in the rear end of the axle 39 of the reverse idle gear, press the axle back and remove the gear 38.

13. Using a puller, remove the rear bearings 5 ​​and 33 of the primary and intermediate shafts.

14. Install the box with the countershaft on top, slide the countershaft forward until the countershaft gear assembly 42 rests in the crankcase to move the front bearing forward.

15. Feed the intermediate shaft back until the inner ring comes out of the front bearing 43.

16. Install the gearbox with the hatch up under the shift mechanism.

17. Remove the input shaft 1, the blocking ring 46 of the fourth gear and the output shaft assembly from the gearbox housing.

18. Remove the circlip 44 and move the intermediate shaft back until the gear cluster stops in the crankcase. Press the countershaft out of the gear cluster through the front opening of the crankcase towards the rear of the transmission. Remove the intermediate shaft and gear assembly from the crankcase.

1. Remove the inner ring 24 (see rice. 190) bearing, thrust washer 2 and gear 3 of the first gear with needle bearing 23 and blocking ring 4.

2. Using a puller, remove the retaining ring 5 of the synchronizer hub of the first and second gears and the thrust washer 22.

3. Remove the synchronizer 6 of the first and second gears together with the gear wheel 8 of the second gear, the blocking ring 19 and the thrust washer 20.

4. Remove the key 21, the circlip 7 and the needle bearing 18 of the second gear.

5. Using a puller, remove the retaining ring 12 of the synchronizer hub of the third and fourth gears.

6. Remove the synchronizer 14 of the third and fourth gears together with the gear wheel 9 of the third gear, the blocking ring 10 and the thrust washer 15.

7. Remove the key 13, circlip 11, spacer 16 and needle bearing 17 of the third gear.

Disassembly of the shift mechanism

1. Unscrew the four bolts of the support 11 (see. rice. 189) of the shift lever and remove the support with lever 7 and compression spring 10.