Contents: Gear ratios ⇓ Data for verification and adjustment ⇓ Differential ⇓ Gearbox oil ⇓ Tightening torques of main threaded…⇓
Depending on the vehicle's configuration, a four- or five-speed gearbox with synchronizers on all forward and reverse gears may be installed, combined with a differential and a transversely mounted main gear on the end of the engine.
Gearbox types:
- cars with engines of all models except B6 EGI: F;
- cars with B6 EGI engine: G.
Gearboxes of types "F" and "G" have the same adjustment parameters, but differ from each other in the following:
- gearbox type "G" fully synchronized;
- in the F type gearbox, a constant mesh reverse intermediate gear is used, while in the G type gearbox, this gear is sliding;
- the hub, sliding clutch and synchronizer of the 5th gear and reverse gear of the type "F" gearbox are installed on the secondary shaft, and in the type "G" gearbox this unit is installed on the primary shaft;
- an additional diaphragm spring is installed on the secondary shaft of the "G" type gearbox.
Gear ratios
Data for verification and adjustment
Clearance between axle and intermediate reverse gear, mm:
- nominal: 0.095-0.318;
- maximum permissible (when worn out): 0,5.
Clearance between the gear shift fork and the synchronizer sliding sleeve, mm:
- nominal: 0.200-0.458;
- maximum permissible (when worn out): 0,5.
Axial clearance between the end face of the locking ring and the end face of the synchronizer gear ring, mm:
- nominal: 1.5;
- maximum permissible (when worn out): 0,8.
Axial runout of gears, mm:
- 1st gear: 0.140-0.370/0.42*;
- II gear: 0.245-0.580/0.63;
- III gear: 0.095-0.380/0.43;
- IV gear: 0.090-0.400/0.45;
- V gear: 0.150-0.262/0.312.
* The numerator indicates the nominal gap, the denominator indicates the maximum permissible gap (when worn out).
Preload of primary and secondary shaft bearings, Nm: 0.10-0.34.
To adjust the bearing preload, adjustment rings with a thickness of 0.20 to 0.55 mm at intervals of 0.05 mm are supplied as spare parts.
Differential
Preload of bearings, Nm: 0.03-0.75.
To adjust the bearing preload, adjustment rings with a thickness of 0.10 to 0.85 mm at intervals of 0.05 mm are supplied as spare parts.
Lateral clearance between the teeth of axle gears and satellites, mm: 0-0.1.
Gearbox oil
Gearbox housing filling capacity, l:
- Gearbox type "F": 3.2;
- Gearbox type "G": 3.35.
Oil used:
- Gearbox type "F": SAE 80 W or SAE 90, API GL4 or GL5;
- Gearbox type "G" automatic transmission oil ATF Dexron II.
Frequency of checking the oil level: every 15,000 km or once a year.
Oil change frequency: every 45,000 km or once every three years.
Tightening torques of main threaded connections, kgf·m
- Bolt for fastening the gearbox housing to the clutch housing: 3.8-5.3.
- Clutch housing to engine block mounting bolt:
- upper: 6.5-9.1;
- lower: 9.1-11.9/6.5-9.1*.
- Reverse idler gear axle lock bolt: 1.9-2.6.
- Reverse idler gear lock bolt nut: 13.0-21.0.
- Bolt for fastening the rear cover to the 5-speed gearbox housing: 0.8-1.1.
- Drain plug: 4.0-5.5.
- Differential driven gear mounting bolt: 7.0-8.5.
- Reverse light switch: 2.5-3.5.
* The denominator shows data for cars with "E" engines, the numerator shows data for cars with "B" engines.