3.1. Coupling

Possible malfunctions of coupling, its drive, their reason and ways of elimination

Features of a design

Fig. 3.1. Coupling: 1 – coupling case; 2, 11, 14, 20, 30 – washers; 3, 16, 21 – nuts; 4, 15 – hairpins of fastening of a case of coupling; 5 – a coupling casing assembled with a press disk; 6 – coupling switching off bearing; 7 – bearing flange; 8 – connecting spring; 9 – cuff assembled; 10 – bolt of fastening of a casing; 12 – adjusting pin; 13 – flywheel; 17 – protective cover of a fork of switching off of coupling; 18 – tubular adjusting pin of a case of coupling; 19 – hairpin of fastening of a starter and case of coupling; 22 – spherical support of a fork; 23 – main shaft of the transmission; 24 – screw of fastening of an arm of a fork; 25 – fork spring; 26 – washer of a spherical support; 27 – coupling switching off fork; 28 – fork pusher; 29 – ottyazhny spring of a fork; 31 – bolt of fastening of an antisplash guard; 32 – antisplash guard; 33 – the conducted disk assembled


On the car dry one-disk coupling with the central press spring and the quencher of tortional fluctuations (damper) mounted on the conducted disk is established; coupling drive hydraulic. The engine UEPA-331 is equipped with coupling of fashion. 2126, the VAZ-2106 engine – production coupling VAZ. Both couplings have an identical design, differ only in the size and a form of details.

Fig. 3.2. Press a clutch plate with a casing assembled: 1 – coupling casing; 2 – press disk; 3, 9 – rivets; 4 – connecting link; 5 – press spring; 6 – lock ring; 7 – basic heel; 8 – coupling finger; 10 – balancing small weight; 11 – central plug; 12 – spring conic ring; 13 – connecting plate


Features of a design are illustrated on the example of the coupling aggregated with the engine of fashion. 331. The main parts of coupling are press a disk with a casing of 5 (fig. 3.1) and the conducted disk 33, placed in the case cast from aluminum alloy 1. The casing fastens to an engine flywheel six bolts 10, and connects to a press disk through a press spring in three couples of elastic connecting plates of 13 (fig. 3.2). The conducted disk is established between a flywheel of the engine and a press disk on vents of a main shaft of the transmission 23 (see fig. 3.1).

Coupling repair
Coupling removal
1. Turn off bolts of fastening of a flange of the back driveshaft to a flange of the leading gear wheel of the back bridge.
2. Turn off bolts of fastening of an intermediate support of driveshafts and disconnect the forward driveshaft from a flange of the elastic coupling.
3. Turn off bolts of fastening of the transmission to a case of coupling and remove a box (see. "Removal of the transmission").

Fig. 3.3. Coupling switching off drive: 1 – main cylinder of coupling; 2 – the feeding tank of the main cylinder of coupling; 3 – connecting tube; 4 – connecting nut; 5 – flexible hose; 6 – working cylinder; 7 – protective cap; 8 – fork pusher; 9 – pusher tip; 10 – protective cover of coupling; 11 – ottyazhny spring of a fork of switching off of coupling; 12 – coupling pedal; 13 – lock-nut; 14 – pusher tip; 15 – braking signal switch; 16 – coupling pedal arm; 17 – finger; 18 – pedal axis; 19 – returnable spring; 20 – nut; 21 – pedal axis plug; 22 – nut; 23 – washer; 24 – forelock; 25 – overlay of a pedal; 26 – protective cap of the valve; 27 – valve of production of air; 28 – coupling switching off fork


4. Remove a lock ring of the working cylinder 6 (fig. 3.3) by means of special kruglogubets then take out the cylinder from an opening in inflow of a case, having pushed it forward. Leave the working cylinder to hang on a connecting hose of the 5th hydraulic actuator of coupling.
5. Turn off bolts 31 (see fig. 3.1) fastenings of a stamped guard 32 to a case of coupling and remove a guard.
6. Turn off nuts of the 16th fastening of a starter to the block of cylinders and remove a starter from hairpins 15.
7. Disconnect fastening of a suspension bracket of the muffler and an exhaust pipe and incline the engine back as far as forward support of an engine mount allow.
8. Turn off nuts of fastening of a case of coupling to the block of cylinders of the engine then remove a case back and remove it from adjusting pins 18 and hairpins of the 4 and 19 fastening to the block of cylinders.
9. Weaken bolts of the 10th fastening of a casing of coupling to a flywheel, consistently turning off them on one turnover of diagonal in order to avoid deformation of a casing.
10. After a vyvertyvaniye of fixing bolts remove a coupling casing from adjusting pins 12 and the conducted disk 33.
Definition of technical condition of coupling
1. At emergence of zadir, забоин, ring рисок and wear tracks of a surface of friction of a flywheel and a press disk, and also at a buckling of the last grinding of their working surfaces is allowed.

Fig. 3.4. Minimum admissible thickness of a press disk


2. The casing of coupling with a press disk assembled is non-demountable knot therefore to grind press the disk is recommended only in the conditions of repair shop. After grinding of a working surface of a press disk its general thickness determined by the size A (fig. 3.4) has to be not less than 24,7 mm, purity of a surface – not lower than 1,6 мк.
3. The working surface of a disk has to be flat, concavity no more than 0,08 mm is allowed, at the same time camber is not allowed.
4. Grinding of a press disk reduces the working effort created by a press spring therefore at assembly of coupling with the repaired press disk for restoration of normal effort of a press spring establish special repair expansion washers on coupling fingers of fastening of a press spring to a coupling casing.
5. Check thickness of the conducted disk assembled with slips in the compressed state under the load of 4220 N (430 kgfs) which is evenly distributed on a surface of slips. Thickness measured on working surfaces of frictional slips has to be 7,1–
7,6 mm. Not parallelism of working surfaces of slips at the specified loading has to be no more than 0,18 mm.
6. Check a face beating of working surfaces of frictional overlays of rather shlitsevy opening of the conducted clutch plate and landing of a disk to vents of a main shaft of the transmission. For check of a face beating put on the conducted disk a shlitsevy mandrel (or a main shaft of the transmission). Rotating a mandrel in the centers, fix indications of indicators which legs directly or via intermediate levers adjoin to working surfaces of frictional overlays of the conducted disk in extreme points. The general indications of each of indicators should not be more than 0,60 mm. If the beating exceeds 0,60 mm, the respective site of the conducted disk can be corrected by means of the bifurcate lever. After that repeatedly check beating size.
Control of key parameters of a casing assembled with a press disk 
1. Establish and reliably fix a casing assembled with a press disk on the flat plate replacing an engine flywheel (see fig. 3.2), with the pro-rate ring 7,35 mm thick enclosed under press a disk (instead of a pro-rate ring it is possible to use three expansion washers of the same thickness which are evenly located on a circle).
2. Check the radial beating of a working surface of a basic heel measured on diameter of 50 mm. At each measurement the indication of the indicator should not be more than 0,38 mm. In case of need for reduction of a beating of a heel pressing or blow to one of three platforms L of a casing of coupling is allowed.
3. The size M has to be within 48,0–51,0 mm.
4. When moving a surface P basic heels on 7,1 mm in the direction of an arrow K withdrawal of a surface of P1 of a press disk in the direction of an arrow N has to be not less than 1,27 mm; at the annex to a surface P basic heels of loading in the direction of an arrow K and withdrawal of a surface of P1 of a press disk from P2 surface on 7,9 mm a beating of a surface of H should not exceed 0,25 mm. Measure a beating and withdrawal of a press disk by means of indicators which legs are established on heads of rivets in places of fastening to a press disk of connecting links.
5. The effort, P basic heels, necessary for movement of a surface, of 7,1 mm in the direction of an arrow K, should not exceed 842 N (86 kgfs). Control of effort is carried out after double movement of a surface P heels in the direction of an arrow K to the situation which is not going beyond the most admissible course of 8,9 mm.
6. At measurement of working effort on a press disk fix it on a flat plate. The effort necessary for movement of a surface of P1 of a press disk in the direction of an arrow N to the situation determined by the size G, not less than 3330 N (340 kgfs). Control of effort is carried out after double movement of a surface P heels in the direction of an arrow K to the situation which is not going beyond the most admissible course of 8,9 mm.
7. When determining working effort on a press disk it is necessary that the rod of a press fell until the effort does not cease to decrease and will not begin to raise. Then, reducing loading, raise a press rod to the provision of the press disk corresponding to the size of 7,35 mm (see fig. 3.2), and record at the same time the valid loading. The course of a press disk is measured the indicator.
8. If the data obtained at control of value of the checked parameters do not meet the specified standards (tab. 3.1), replace a coupling casing assembled.

Table 3.1 the Nominal sizes, admissions, gaps and tightnesses in the main interfaced details of coupling and its drive

Replacement of a basic heel
The basic heel 7 (see fig. 3.2) is kept on a press spring by the 5th spring conic ring 12 and the central plug 11 which after installation of a basic heel in a cut of a press spring is inserted against the stop into a fillet on the internal diameter of a heel and zakernen in six places by cave-in of the central plug 11 in the radial direction in a flute on an internal surface of a heel, as shown in a note of I. The spring conic ring 12 due to the elasticity chooses axial gaps after assembly of a heel with a press spring, and also compensates in certain limits wear of contact surfaces of these details in use. At considerable wear which is not compensated by elasticity of a spring conic ring any more or when weakening the last as a result of considerable heating of a working surface of a heel because of violations of the rules of operation of the car fastening of a heel is weakened and, as a result, at start-off from the place and during the movement of the car during the work of coupling characteristic jingle and knock appear.
For replacement of a worn-out basic heel execute the following.

Fig. 3.5. Removal of the central plug of fastening of a basic heel: 1 – central plug; 2 – chisel


Fig. 3.6. Fastening in a vice of the basis of the repair tool with the fixing mandrel


1. Remove the central plug 1 (fig. 3.5) of fastening of a heel, having deformed a flange of the central plug by means of the hammer and a chisel 2. Not to damage a basic heel and other details of coupling during removal of the plug, place a basic heel in the fixing mandrel of the repair tool (fig. 3.6) which basis has to keep reliably in a vice. In the presence of the lathe cut off a cutter a persistent flange of the central plug.
2. Remove a basic heel.

Fig. 3.7. The ends of rychazhok of a press spring (values of admissible wear are specified)


3. Examine surfaces of petals of a press spring in places of contact with a heel. If after cleaning of surfaces of the worn-out ends of petals of a press spring the sizes do not exceed specified fig. 3.7, then the spring can be used for assembly with a new basic heel. Check also height of a spring conic ring 12 (see fig. 3.2) which in a free state has to be 2,5–2,8 mm. With a smaller height replace a ring new.

Fig. 3.8. A general view of a set of the repair tool for installation of a basic heel: 1 – basis; 2 – the fixing mandrel; 3 – a guide for a zakernivaniye; 4 – core


Fig. 3.9. Details of the repair tool for installation of a basic heel: and – the basis; – a guide for a zakernivaniye; in – a core


4. For installation of a new basic heel make a set of the repair tool (fig. 3.8). The sizes and data on material and heat treatment of details of a set are given in fig. 3.9.
5. Clear all details and a set of the repair tool of dirt and lubricant.
6. Clamp in a vice the basis of a set of the repair tool with the fixing mandrel (see fig. 3.6).
7. Establish in the basic heel fixing a mandrel by a flat working end face down.
8. Grease with a thin layer of LSTs-15 lubricant working surfaces of tips of petals of a press spring and establish a coupling casing on a basic heel so that the working surface of a press disk was turned up, as shown in fig. 3.6. At the same time track that petals of a press spring settled down between ledges on a radial surface of a heel.

Fig. 3.10. Installation of the central plug of fastening of a basic heel and spring ring: 1 – central plug; 2 – spring conic ring


9. Install according to fig. 3.10 a spring conic ring 2 on the central plug 1 and insert the plug into an opening of a press spring.

Fig. 3.11. Installation of device for a zakernivaniye of the central plug at assembly: 1 – a guide for a zakernivaniye; 2 – central plug


10. Screw a guide of 1 (fig. 3.11) for a zakernivaniye in adaptation basis to the full, having pressed the central plug against the stop in an end face of a flange of a basic heel.

Fig. 3.12. Zakernivaniye of the central plug at assembly: 1 – core; 2 – central plug; 3 – spring ring; 4 – diaphragm spring; 5 – basic heel; 6 – the fixing mandrel; 7 – a guide for a kerneniye


11. By means of a core of 1 (fig. 3.12) you zakernit the central plug 2 in a flute on an internal surface of a basic heel in six places which are evenly located on a circle. At the same time you hold a core as it is possible more precisely at an angle 30 ° to a horizontal. A flat part of a core at the same time has to lean on the platform of a guide for a zakernivaniye.
Replacement of frictional overlays of the conducted clutch plate
In spare parts the special set 412-1601954-20 – two frictional slips with rivets which can be used for replacement of defective slips is delivered.

       PREVENTION
It is not recommended to sort the conducted clutch plate and to replace its details, except frictional slips. At wear or breakage of details of the conducted disk (excepting wear of working surfaces of frictional slips), loss of elasticity of spring plates and a buckling the conducted disk (if it cannot be corrected) should be replaced new.

1. Carefully, without having touched spring plates of a disk, drill a drill with a diameter of 3,4 mm brass rivets, the fixing frictional slips to spring plates of the conducted disk, and remove slips.
2. Attentively examine spring plates of the conducted disk and check whether there are no cracks on them, deep scratches on an external contour and about openings. Otherwise replace a disk.

Fig. 3.13. The conducted clutch plate: 1 – frictional slip; 2 – rivet of fastening of frictional slips; 3 – rivet; 4 – damper plate; 5 – damper spring; 6 – spring ring; 7 – a nave of the conducted disk; 8 – persistent ring of a damper; 9 – frictional rings; 10 – persistent finger; 11 – the conducted disk; 12 – spring plate


3. Impose a frictional overlay for spring plates of a disk so that openings in the spring plates turned by the convex party to a slip, coincided with zenkovanny openings of a frictional slip. A slip arrange so that zenkovanny openings were turned outside by the big diameter (fig. 3.13).

       NOTE
In the absence of the mentioned special sets it is possible, using the conducted disk as the conductor, drill in new frictional slips twenty openings with a diameter of 4,1+0,16 mm, ten of which (through one) ream to diameter of 8 mm, then ream a drill with a diameter of 8,5 mm with the angle of sharpening 140 ° the remained ten openings, having sustained the sizes specified in section

Fig. 3.14. A frictional overlay of the conducted clutch plate V-in in fig. 3.14.




4. Insert brass tubular rivets 2 so that their heads settled down from the outer side of a frictional slip 1, and it is accurate to their rasklepayta from spring plates by means of a special mandrel or on the riveting machine.
5. In the same way, as in the previous point, a priklepayta the second frictional slip. At the same time zenkovanny openings of one slip have to coincide with nezenkovanny openings another.
6. After a priklepka of both frictional slips check the provision of heads of rivets: they have to be drowned rather working surface not less than on 1,0 mm. In the absence of brass rivets of factory production (normals) they can be made according to the drawing provided on fig. 3.13.
Replacement of a fork of switching off of coupling
1. Remove a coupling case from the car.
2. Disconnect an ottyazhny spring 29 (see fig. 3.1) from a fork of the 27th switching off of coupling.
3. Remove from the directing plug the coupling switching off bearing 6 assembled with a switching off fork.
4. Disconnect a fork of switching off of coupling from a spherical support 22 (the fork fastens to a support a spring 25) and take out a fork from a rubber cover 17.
5. Remove a connecting spring 8 and separate a fork and the bearing.
6. If the fork was bent, burst or the contact surfaces of her pads are worn-out, replace a fork.
7. You carry out assembly of a fork of switching off of coupling in the return sequence. Before assembly the adjoining surfaces of the directing plug, the bearing, grease forks of switching off of coupling and a spherical support of a fork with LSTs-15 lubricant or graphitic lubricant.
Replacement of the bearing of switching off of coupling assembled with a casing
1. Remove the bearing from the directing plug (see. "Replacement of a fork of switching off of coupling").
2. By means of the screw-driver unbend four ledges

Fig. 3.15. Dismantling of the bearing coupling vyklyuchekiya: 1 – bearing; 2 – casing; 3 – wavy spring; 4 – bearing flange; In, With, E – the greased surfaces; Д – casing ledges D casings of 2 (fig. 3.15) of the bearing on a corner 90 °.


3. Remove from a flange the 4th bearing 1 and a wavy spring 3.
4. If height of a spring 3 under effort (100±10) N or (10,2±1) kgfs less than 1,5 mm, replace a spring.
5. The bearing has to be turned freely, without jammings, lubricant should not follow from it. Otherwise replace the bearing.
6. Examine the working surface of the directing plug and a landing opening of the bearing of switching off of coupling which should not have zadir and noticeable wear tracks. Replace worn-out details.
7. You carry out assembly of the bearing with a casing upside-down, previously having greased with a thin layer of lubricant of a surface: In – a flange, With – an end face of an external ring of the bearing, E – an internal end face of a casing. After assembly and installation of the bearing check a free wheeling of the external end of a fork.
Features of control and repair of coupling VAZ

Fig. 3.16. Coupling control: 1 – persistent flange of a press spring; 2 – central press spring; 3 – press disk; 4 – ring


Control of coupling is carried out on the basis which imitates a flywheel of the engine and has the metal intermediate ring of 4 (fig. 3.16) 8,2 mm thick replacing the conducted disk. Having fixed a coupling casing, execute four courses of switching off, equal 8–9 mm. To the course of switching off of 8 mm there has to correspond movement of a press disk of 1,6–1,7 mm (the smallest admissible – 1,4 mm).
The distance from the basis to a working surface of a frictional ring of a persistent flange has to be 40–43 mm. In the course of work as a result of wear of the rubbing surfaces of clutch plates this size increases. If it reaches 48 mm or movement of a press disk will be less than 1,4 mm, assembled with a press disk replace a coupling casing.

Fig. 3.17. Replacement of frictional overlays of the conducted disk: 1 – mandrel 67.7851.9500; 2 – the conducted disk; 3 – conductor 67.7822.9517


Replace frictional overlays of the conducted disk at emergence of cracks, reduction of distance between a rivet and a working surface to 0,2 mm, and also at unilateral teases. At repair of the conducted disk and replacement of frictional slips use adaptation 67.7822.9517 (fig. 3.17).

Fig. 3.18. Editing of the conducted clutch plate


Razvaltsovanny rivets should not have gaps. The beating of a working surface of frictional slips should not exceed 0,5 mm. If it is more, then a disk correct (fig. 3.18) or replace new. At emergence on the conducted disk or springs of a damper of cracks, replace the conducted disk assembled.
Removal and dismantling of the drive of coupling
1. Having turned off a connecting nut 4 (see fig. 3.3), disconnect a tube 3 drives of coupling from the flexible hose 5 connected to the working cylinder.
2. Squeezing out a coupling pedal, merge in a pure vessel brake fluid from the main and working cylinders of a hydraulic actuator.
3. Rasshplintuyte the finger 17 connecting a pedal to a pusher of the main cylinder and then remove a washer and a finger.
4. Disconnect a tube 3 from the main cylinder, having turned out a nut from the case of the main cylinder.
5. Turn off two nuts of fastening of the main cylinder of a hydraulic actuator of coupling from a board of a front and remove the main cylinder.

Fig. 3.19. Main cylinder of the drive of coupling: 1 – tank; 2 – tank cover; 3 – uspokoitel; 4 – washer; 5 – bolt; 6 – hairpin of fastening of the main cylinder; 7 – protective cap; 8 – piston pusher; 9 – lock-nut; 10 – pusher tip; 11 – lock ring; 12 – persistent washer; 13 – external sealing cuff of the piston; 14 – piston; 15 – piston valve; 16 – internal sealing cuff of the main cylinder; 17 – case of the main cylinder; 18 – returnable spring; 19 – union of the main cylinder; and – an obligatory gap of 0,2-1,0 mm; In – a perepuskny opening; With – a compensation opening


6. Turn off a cover 2 tanks (fig. 3.19) and take out an uspokoitel 3.
7. Merge the remains of working liquid from a tank.
8. Having slightly clamped the main cylinder in a vice or special adaptation, turn off a bolt of the 5th fastening of a tank to the case of the main cylinder then remove a tank 1 and laying of the case of a tank.
9. Take off a protective cap 7 from bore of the case of the main cylinder and shift it along a pusher 8.

Fig. 3.20. Kruglogubtsa for removal and installation of a lock ring of the main cylinder


10. Take out from the cylinder by means of kruglogubets (fig. 3.20) a lock ring 11 (see fig. 3.19) a persistent washer 12, and then a pusher 8 assembled with a persistent washer. In need of dismantling of a pusher turn off from it a tip and a lock-nut.
11. Take out from the cylinder case 17 the piston 14 assembled with a cuff 13, the piston valve 15, a sealing cuff 16, a returnable spring of the 18th piston assembled with a basic cup.
12. Carefully remove from the piston an external sealing cuff 13. Does not follow without need to unscrew hairpins of the 6th fastening of the main cylinder from its flange.
.

Fig. 3.21. Working cylinder of the drive of coupling: 1 – cylinder case; 2 – expansion fungus; 3 – sealing cuff; 4 – piston; 5 – protective cap; 6 – lock ring; 7 – valve of production of air; 8 – protective cap of the valve; 9 – spring


13. For removal of the working cylinder of the drive of coupling of fashion. 2126 by means of kruglogubets remove an ottyazhny spring 11 (see fig. 3.3) coupling switching off forks, a lock ring 6 (see fig. 3.21) and take out the cylinder from an opening in inflow of a case, having pushed it forward.
14. Take out a pusher 8 (see fig. 3.3) from the working cylinder. If it is necessary to sort a pusher, turn off from it a tip and a lock-nut.
15. Take off from bore of the case of the working cylinder a protective cap 5 (fig. 3.21) and from a conic nose of the valve 7 of production of air a protective rubber cap 8.
16. Take out a lock ring 6, the piston 4, a sealing cuff 3, an expansion fungus 2, a spring 9 from the cylinder, turn out the last of the case of the cylinder the valve 7 of production of air. In order to avoid damage of sealing cuffs of pistons of the main and working cylinders delete pistons from cylinders with a stream of compressed air, giving it to an opening for connection of the pipeline.

Fig. 3.22. Working cylinder and fork of switching off of coupling: 1 – coupling switching off bearing; 2 – spherical support; 3 – coupling switching off fork; 4 – pusher; 5 – adjusting nut; 6 – lock-nut; 7 – ottyazhny spring; 8 – case stopper; 9 – the union for pumping; 10 – cylinder case; 11 – sealing ring; 12 – protective cap; 13 – piston; 14 – sealant; 15 – plate; 16 – spring; 17 – basic washer; 18 – lock ring


17. For removal of the working cylinder of the drive of coupling VAZ disconnect an ottyazhny spring of 7 (fig. 3.22), remove the forelock from the end of a pusher, and then the working cylinder, having turned off two bolts of fastening.

Fig. 3.23. Coupling drive cylinder details (working cylinder): 1 – case; 2 – union; 3 – cap; 4 – pusher; 5 – sealing ring; 6 – piston; 7 – sealing ring; 8 – plate; 9 – spring; 10 – washer; 11 – lock ring


18. Turn out a stopper, remove a protective rubber cap of 3 (fig. 3.23) together with a pusher 4, take out the piston and sort it, previously having removed a lock ring 11.
19. After dismantling of working and main cylinders carefully wash out all details fresh brake fluid, examine and replace worn-out details.

       RECOMMENDATION
When replacing of the deformed coupling case new it is expedient to replace also a main shaft of the transmission.

Repair of pedal knot (pedals of coupling and a brake with an arm assembled)
1. Disconnect tips of 14 pushers (see fig. 3.3) from pedals of coupling and a brake.
2. Turn off four nuts of fastening of a steering column to an arm of pedal knot and lower a column down.
3. Disconnect wires from the braking signal switch.
4. Turn off by means of rotation of a nut of the 20th fastening of the block of pedals to a board of a front and remove pedal knot.
5. Turn off nuts 22 fastenings of axes of pedals of coupling and a brake.
6. Beat out axes of pedals of coupling and a brake from cheeks in an arm of pedals. It is necessary to do it carefully not to damage a carving of axes.
7. Take out pedals of coupling and a brake from apertures of an arm and remove from a nave of pedals returnable springs 19.
8. Take out two plastic plugs 21 from naves of pedals of coupling and a brake.
9. Remove from platforms of pedals rubber slips 25.
10. Weaken a nut and turn out the braking signal switch 15 from an arm.
11. Examine working surfaces of axes of pedals and plastic plugs. At detection superficial рисок or corrosion traces on surfaces of axes polish them a small skin granularity 10-M40. If necessary carefully smooth out agnails at end faces of plastic plugs or replace them new.
12. Replace the weakened returnable springs of pedals of coupling and a brake.
13. You carry out assembly of pedal knot upside-down, previously having greased with the USSA graphitic lubricant (State standard specification 3333-80) the rubbing surfaces of axes of pedals of coupling, a brake and plugs.
14. After assembly check ease of movement of pedals on axes.
Installation of coupling on an engine flywheel
1. Attentively examine a working surface of a flywheel and be convinced of lack of zadir and забоин. Check a flywheel beating which should not exceed 0,2 mm. If the beating is more specified, it should be eliminated. Otherwise wear of shliyets in a nave of the conducted disk in use increases, breakthroughs and jolting in operating time of knot will appear.
2. Replace the defective forward bearing of a main shaft of the transmission pressed in an end face of a bent shaft. If necessary put in it lubricant.
3. Attentively examine frictional overlays of the conducted disk. Dirt and traces of oil on their working surface are inadmissible.
4. Insert the conducted disk into a coupling casing so that the plate 4 dampers (see fig. 3.13) was turned to a press disk.
5. From a press spring insert into a nave of the conducted disk a special mandrel for centering of a disk and establish a coupling casing on three adjusting pins 12 (see fig. 3.1), pressed in an engine flywheel. At the same time enter the end of a mandrel into an internal holder of the forward bearing of the main shaft of the transmission pressed in an end face of a bent shaft. In the absence of a special mandrel it is possible to use a main shaft of the transmission.
6. Screw six bolts of the 10th fastening of a casing of coupling to a flywheel in carving openings on one turn, having established under them spring washers. Then serially on diagonal tighten all bolts on one turn for every time.
7. Take out a shlitsevy mandrel from a nave of the conducted clutch plate.
8. Establish on four hairpins 4 and 15 wrapped in a back end face of the block of cylinders, the coupling case which is previously collected with an epiploon of a main shaft of the transmission, a fork of switching off of coupling and a cover of a fork. Before a press fitting in a coupling case nest oil an epiploon of a main shaft engine.
9. Center a coupling case on two adjusting pins 18 pressed in the block of cylinders then tighten four nuts of fastening of a case, having established under them spring washers.
10. Install the working cylinder of coupling on a case (see. "Assembly and adjustment of the drive of coupling").
11. Apply a thin film of LSTs-15 lubricant or graphitic on the aligning sock and vents of a main shaft of the transmission and install the transmission on the engine.
12. Check quality of assembly and work of coupling on the car. You carry out an inspection at first idling the engine pressing of a pedal of coupling against the stop in a floor, then at start-off of the car from the place and on the run, switching transfers at the corresponding frequency of rotation of a bent shaft of the engine.
13. If the free wheeling of the end of a fork of switching off of coupling (4,5–5,5 mm) is adjusted correctly, at switching off of coupling without pedal delays in intermediate positions in the mechanism of coupling and its drive knocks or noise should not be listened.
14. At a smooth otpuskaniye of a pedal of coupling the car has to start smoothly, and when switching with the lowest to the highest transfer – to move without breakthroughs.

Table 3.2  Maximum permissible wear in the main details of the mechanism of coupling and its drive

Assembly and adjustment of the drive of coupling
1. Before assembly carefully wash out all details of the main and working cylinders fresh brake fluid.
2. Wipe mirrors of working and main cylinders with the pure napkin moistened with brake fluid and attentively examine, it is desirable with illumination. If on mirrors of cylinders insignificant traces of corrosion, small teases or wear, grind or an otkhoninguyta of a mirror of cylinders. At the same time increase in diameter of cylinders up to 22,17 mm is allowed. In this case at assembly use standard (new) sealing rubber cuffs. It is necessary to notice that uniform wear of working surfaces of the main and working cylinders of coupling has no significant effect on operability of the drive of coupling: sealing cuffs are established in cylinders with a considerable tightness therefore wear of the rubbing couple of details is compensated by elasticity of a cuff.
3. In the presence of sinks on a mirror replace cylinders new. Grease rubber sealing cuffs, pistons and mirrors of cylinders before assembly with fresh brake fluid.
4. When cleaning the working cylinder remove, for example with the pointed match, dirt from a flute at the bottom of the cylinder. Even the smallest particles of dirt getting after assembly under a cuff can cause to flow and the admission of air. Clear also an opening for a liquid supply.
5. Attentively examine carving openings of cylinders. The cut-off and crumpled carving is inadmissible.
6. Replace the hardened cuffs or with defects on their working edges, and also the protective rubber covers torn or lost elasticity.
7. In the main cylinder (see fig. 3.19) carefully clean a perepuskny opening In the pointed match, and a compensation opening With – the soft blunted wire with a diameter of 0,6 mm. Clear also air vent in a tank stopper.

Fig. 3.24. Flaring of the ends of a connecting tube


8. The connecting tube and a hose between the main and working cylinders have to be carefully cleared and washed out. Attentively examine connecting cones and a carving of unions. The sizes of the ends of a connecting tube after flaring are given in fig. 3.24.

  Table 3.3 Characteristic of Springs of the Drive of Coupling

9. Check elasticity of coupling and returnable springs. Their efforts have to correspond to these tab. 3.3. If springs weakened, replace them.
10. Balance of assembly of working and main cylinders see. "Removal and dismantling of the drive of coupling" taking into account the following additions.
11. After assembly of the main cylinder of coupling press a pusher against the stop and sharply release it. The piston under the influence of a returnable spring has to come back vigorously against the stop to a washer 12 (see fig. 3.19). Otherwise check elasticity of a returnable spring (see in tab. 3.3) and if necessary replace it.
12. In a starting position (the piston rests against a persistent washer) between a spherical head of a pusher and a nest of the piston there has to be a gap of 0,2-1,0 mm provided with the sizes of the entering details. Lack of a gap is unacceptable.
13. Check by means of a soft wire with a diameter no more than 0,6 mm whether the compensation opening From the cylinder is blocked by edge of a cuff of the 16th piston. If it is blocked, it is necessary to disassemble the cylinder, to find out and remove the cause of overlapping of an opening. If necessary replace defective parts then finally collect the main cylinder of coupling.
14. If when dismantling cylinders fixing hairpins 6 were turned out from a flange, they should be turned in a flange, having sustained the size of 20-22 mm from a flange end face to the speaker of the end of a hairpin.
15. Install the working cylinder of the drive of coupling of fashion. 2126 on the engine for what insert it into a cylindrical opening of inflow of a case of coupling so that the cylinder rested the special platform against the lower end face of the block of cylinders. Then fix the cylinder from shift in the axial direction a lock ring which establish in a flute on the outer diameter of the cylinder by means of special kruglogubets.
16. Insert the spherical end of a pusher 8 (see fig. 3.3) forks into deepening of the piston of the working cylinder, and then connect a tip of the 9th pusher to a coupling switching off fork. Pusher length assembled with a tip until the end of a spherical part of a tip has to be 123 mm.
17. Put on an ottyazhny spring 29 (see fig. 3.1) one end in an opening on a coupling case, and to others – in a cut on a fork.

Fig. 1.31. Adjustment of the hydraulic drive of switching off of coupling: 1 – valve of production of air; 2 – pusher; 3 – nut; 4 – pusher tip; 5 – coupling switching off fork; 6 – protective cover


18. Check and if necessary adjust a free wheeling of the external end of a fork of switching off of coupling which has to be 4,5–5,5 mm. The specified size of a free wheeling of a fork corresponds to S gap size between the bearing and a heel (mm S=2,5). For check shift a pusher of 2 (fig. 1.31) to the left against the stop in the piston of the working cylinder and press a fork 5 to a tip 4 rods in the direction opposite to an arrow X. Then move a fork concerning a tip in the direction of an arrow X against the stop of the bearing to a heel. Movement of the end of a fork from the first situation in the second has to be 4,5–5,5 mm. For adjustment turn off a lock-nut 3 and, turning or turning off a tip, achieve the required movement of a fork. Then, holding a tip in the chosen situation, tighten a lock-nut.
19. At the coupling drive VAZ a free wheeling of a fork of switching off of coupling of 4-5 mm. It is regulated by a nut 5 (see fig. 3.22) which is fixed by a lock-nut 6.
20. Insert the main cylinder of coupling assembled with hairpins from a motor compartment into front board openings.
21. Install into place the block of pedals and "acquire" nuts 20 (see fig. 3.3) with the enclosed washers. Tighten nuts.
22. Connect a tip of the 14th pusher of the main cylinder to a pedal of the 12th coupling, having implanted a finger 17 so that the head of a finger was at the left concerning a pedal (in the direction of the movement of the car), and зашплинтовав it.
23. Check a full speed of a pedal of coupling which has to be 135–140 mm. If necessary adjust a starting position of a pedal of coupling by change of length of draft of a pusher. For increase in the course of a pedal it is necessary to extend a pusher (to turn out it from a tip 14), for reduction of the course – to truncate a pusher (to screw it in a tip.) After the end of adjustment of provision of a pedal reliably record a pusher from a provorachivaniye, having tightened a lock-nut 13. It is necessary to watch that platforms of pedals of coupling and a brake were at one level, the difference no more than 5 mm is allowed.
24. Wash out fresh brake fluid and blow compressed air a connecting tube 3 and a hose 5.
25. Connect a hose 5 to the working cylinder through an adapter and sealing washers. Pass the second end of a hose through an opening in an arm and fix by a nut.
26. Connect the top end of a connecting tube to the main cylinder of coupling, having screwed a connecting nut in a carving opening of the union of the main cylinder. Connect the lower end of a tube to a hose on an arm of a board of a front and wrap a connecting nut.
27. Fill in fresh brake fluid in system of a hydraulic actuator of coupling and pump over system.
       PREVENTIONS
It is impossible to mix brake fluids of different brands. It is strictly forbidden to add to system at least the most insignificant amount of mineral oils, gasoline, kerosene as they cause destruction of rubber details. It is necessary to remember that brake fluid leaves spots on the painted surfaces of a body and other details.

Pumping of a hydraulic actuator of coupling
1. Fill a tank of the main cylinder of the drive of coupling with brake fluid to level between two ring risks on the tank case.
2. Remove a protective cap 8 (see fig. 3.21) and put on a rubber hose a valve 7 head. Ship the free end of a hose in the brake fluid poured in pure transparent capacity.
3. Sharply press a coupling pedal 2–3 times (with an interval between pressing 1–2 c) and, holding a pedal of pressed, unscrew the valve 7 of production of air on 1/2–1 turn. Under the influence of pressure created in system, a part of liquid and the air which is contained in it (in the form of bubbles) will leave through a hose in the container with liquid.
4. After liquid ceases to follow from a hose, wrap the valve of production of air.
5. Repeat operations 3, 4 until release of air from the following liquid completely does not stop. At the same time you watch liquid level in a tank and do not allow its decrease more than on 2/3 from normal.
6. Holding a pedal in the pressed state, wrap the valve, remove a hose, put on a protective cap the valve and add liquid in a tank to normal level.
7. After pumping press a pedal against the stop and measure the size of movement of a pusher of the working cylinder which has to be not less than 19 mm. Otherwise it is necessary to continue pumping as in system there was an air.

       NOTE
Full filling of system of a hydraulic actuator of coupling requires about 100 g of brake fluid.

8. Correctly pumped over system of a hydraulic actuator of coupling has to provide smooth inclusion of a backing in the transmission. If at the pedal of coupling which is squeezed out against the stop in a floor shock inclusion of a backing takes place, be convinced of correctness of installation of a free wheeling of the external end of a fork of switching off of coupling (see. "Assembly and adjustment of the drive of coupling" subitems 18 and 19) and in serviceability of coupling.
9. At the pedal of coupling pressed against the stop check tightness of connections of a tube and hose with the main and working cylinders. At leak of liquid tighten connecting nuts, the lower union of a hose and an adapter before elimination of a leak.
10. Launch the engine and press several times a coupling pedal against the stop. At the same time jammings, knocks, extraneous noises or any other defects should not be found.
Replacement of a case of coupling
Need of replacement of a case of coupling can arise at its breakage or deformation as a result of blow against a road obstacle.
1. Press an epiploon of a main shaft of the transmission in a new case of coupling.
2. Establish a coupling switching off fork on a case.
3. Establish a case on the pins pressed in a back end face of the block of cylinders then by means of a special face key delay nuts with spring washers of fastening of a case to the block of cylinders of the engine with long rotation, and after installation of a starter – two nuts of fastening of a starter to the cylinder block.
Connection of a case of coupling of VAZ-2106 with the Izh-2126 transmission
On the Izh-2126 cars with the engine UEPA-331 the Izh-2126 five-speed transmission in which transfer numbers are executed most optimum from the point of view of providing the best indicators of the car on dispersal and fuel consumption is installed.

Fig. 3.25. Connection of a case of coupling of VAZ-2106 with the Izh-2126 transmission: 1 – case of coupling of VAZ-2106; 2 – pro-rate; 3 – laying; 4 – Izh-2126 transmission


For the purpose of a possibility of installation of this box the pro-rate which fastens to a coupling case then the transmission fastens to a pro-rate (fig. 3.25) is installed on the Izh-2126 cars with the VAZ-2106 engine between a case of coupling of VAZ-2106 and the Izh-2126 transmission. At the same time the main shaft in the transmission 52 mm longer and has designation not 2126-1701030, but 2126-1701030-80.