Replacing the clutch and fork on a gazelle car with your own hands

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Replacing the clutch fork

Replacing the clutch fork on the Gazelle Business model is very easy to do; you do not need to remove the gearbox for this. This type of repair can also be done by yourself.

To replace the fork, unscrew the two bolts of the clutch slave cylinder (CLC), the cylinder on the hose is moved to the side. We remove the old plug and install a new one. You need to make sure that the fork hits the special ebb of the release bearing clutch, otherwise the clutch pedal will not be pressed normally.

Having installed the new fork, we press the control center through the rod with our hands, bring it to the mounting points, and fix the cylinder with bolts. Of course, the clutch hose can be unscrewed and it will be easier to install the control unit, but then you will have to bleed the clutch. We have described replacing the plug in the simplest and most optimal way.

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Operating principle of the clutch system

To transmit torque to the driving wheels of the vehicle from the engine crankshaft, a box is provided, because smooth transmission of torque from the motor to the wheels is unprofitable. The car will not be able to move without a clutch, and the operation of the power unit itself will be ineffective.

For comfortable operation of the power plant, the torque removed from the crankshaft must be changed in advance in the gearbox (gearbox). After which it moves to the driven axle. Since changing gears forces the gearbox gears to spin, which hit each other with force, it can be difficult to change gears. If the box is always connected to the unit, in order to completely stop the vehicle, it will be necessary to stop the motor.

Clutch operation in a Gazelle car

To solve these problems, the car is equipped with a clutch, which is a special box assembly. It promotes temporary separation of the engine and gearbox, which leads to an interruption of torque. By pressing the clutch pedal, you can change gears or stop the car. The clutch allows the car to move off smoothly and accelerate.

Read:

The principle of its operation is similar for any brand of car. It eliminates the possibility of rapid wear of components and parts that connect the power plant and the gearbox.

The clutch pressure plate, attached to the housing, presses the driven disc against the flywheel. The disk hub attached to the input shaft must be able to move freely along it. The hub body is equipped with damper springs, which act as vibration dampers and ensure smooth operation.

To make the required force when pressing, a spring with petals is provided, which are exposed to the release bearing. It is a connecting link between the drive and the clutch, onto which the fork with the lever is attached. Another lever or cable is attached to its end, leading to the clutch pedal.

Replacing the ZMZ-402 clutch fork on the Volga

Replaced early in the afternoon on a weekend

I'm
using the clutch fork
.

How to replace the clutch fork without removing the gearbox.

how to replace clutch fork

VAZ-2101-2107 cars without removing the gearbox. VKontakte groups for repairs...

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VESKO-TRANS.RU

AutoNews / Reviews / Tests

Replacing the Gazelle 406 Clutch Fork

Adjusting and replacing Gazelle clutch

To avoid vehicle malfunction, you can replace the clutch driven cylinder or Gazelle cylinder and other parts. It is necessary to replace the clutch kit and other components as soon as possible so that the vehicle can be diagnosed and repaired if necessary. This will help avoid breakdowns and accidents on the highway in the future.

Gazelle clutch diagram

Operating principle of the clutch system

There is a box for transmitting torque to the driving wheels of the car from the engine crankshaft, since smooth transmission of torque from the engine to the wheels is disadvantageous. The car will not be able to drive without a clutch, and the power supply itself will be ineffective.

For comfortable operation of the power plant, it is necessary to first change the torque removed from the crankshaft in the gearbox (gearbox). It then runs along the driven axis. Because changing gears makes it difficult to change gears that hit each other hard, changing gears is difficult. If the box is permanently connected to the device, the engine must be stopped to bring the vehicle to a complete stop.

Clutch operation in a gazelle car

To combat these obstacles, the car is equipped with a clutch, which is a special box assembly. This promotes temporary separation of the engine and transmission, resulting in torque interruption. By pressing the clutch pedal, you can change gears or stop the car. The clutch allows the car to move and accelerate smoothly.

The principle of its operation is similar for any brand of car. This eliminates the possibility of severe wear of components and parts connecting the power plant and the box.

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Operating principle of the clutch system

Clutch operation in a Gazelle car

To solve these problems, the car is equipped with a clutch, which is a special gearbox assembly. It promotes temporary disconnection of the engine and gearbox, which leads to an interruption of torque. By pressing the clutch pedal, you can change gears or stop the car. The clutch allows the car to move off smoothly and accelerate.

The principle of its operation is similar for any brand of car. It eliminates the possibility of rapid wear of components and parts that connect the power plant and the gearbox.

To make the required force when pressing, a spring with petals is provided, which are exposed to the release bearing. It is a connecting link between the drive and the clutch, onto which the fork with the lever is attached. Another lever or cable is attached to its end, leading to the clutch pedal.

Replacing the ZMZ-402 clutch fork on the Volga

Early in the morning on the weekend I changed the clutch fork

How to replace the clutch fork without removing the gearbox.

how to replace clutch fork

VAZ-2101-2107 cars without removing the gearbox. VKontakte groups for repairs...

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Before you start adjusting

Clutch adjustment is carried out only if the unit is fully operational. The GAZelle's clutch is very fragile and often breaks even due to slight overload, so problems can arise even before any adjustment work begins. Not the highest quality production technology has become the main reason why parts of the assembly fail almost one after another. It is worth checking whether all elements of the clutch structure are intact before starting other work. What you need to check most carefully:

The working cylinder often breaks. It is worth checking first of all for leaks, breakdowns, and damage to the hoses. If it does not work properly, the gear shift system will slow down, and this may cause other driving problems (jerking, loss of speed).

This is what the Gazelle clutch slave cylinder looks like

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How to change the clutch on a Gazelle

Home » Repair and service » How to change the clutch on a Gazelle

Content

Replacing the Gazelle clutch

Replacing the clutch fork

Replacement video

Replacing the clutch of a Gazelle car is required quite often, as it is a vulnerable point.

The machine is mainly intended for business, the components and assemblies of which always operate under load.

Therefore, the service life of the parts is limited; on average, the clutch requires replacement every 50–70 thousand kilometers. As a rule, it changes as a set (pressure disk, driven disk, release bearing).

Gazelle business clutch replacement

Replacing the clutch of Gazelle business model cars is not difficult to do. To do this, you just need the appropriate tool. Work must be performed on a car lift or in a pit.

You can replace the disk or the entire set yourself. For example, let's take a Gazelle with a ZMZ 40524 engine (it is from the ZMZ 406 engine family).

We put the car in the pit and first of all remove the gearshift lever. Before removing the lever, it must be set to the neutral position. Raise the rubber casing.

We find the cone nut, unscrew it and pull out the lever.

We make marks on the driveshaft and rear axle shank.

note

Marks are made in order to place the shaft in the same position during assembly. If the “cardan” is not placed according to the marks, vibration may occur.

Then unscrew the gearbox yoke (8 bolts along the edges) and pull out the shaft. Before removing the driveshaft, it is advisable to drain the gearbox oil.

Further disassembly:

We disconnect the wires going to the gearbox;
We disconnect the fastening of the gearbox bracket to the exhaust pipe of the muffler;
We completely remove the gearbox traverse, do this carefully, since the engine and gearbox will go down;
Then we unscrew the nuts securing the gearbox itself and dismantle it.

We unscrew the fastening of the clutch slave cylinder, move the cylinder to the side, and remove the fork.

We dismantle the clutch housing (“bell”), first the lower aluminum housing amplifier, then the housing itself.

Unscrew the six bolts on the basket. Everything has been taken apart.

We take a new set - basket, disk, release bearing, and begin assembly. In order to install the gearbox without problems, the driven disk must be centered, and then the “basket” bolts must be tightened.

The bolts need to be tightened evenly in a circle, and not immediately on one side. For alignment, you can use a special mandrel or any input shaft of the Gazelevskaya or Volgovskaya gearbox.

The shaft will fit even a 4-speed gearbox.

Then we assemble everything further in reverse order. It is convenient to immediately put the release bearing on the flange of the input shaft of the box, having previously placed a sponge soaked in thick lubricant under it. The sponge can be soaked in transmission oil.

To fasten the gearbox yoke alone, you will need to jack up the gearbox; it is more convenient to do this operation together. After assembly, you should fill the gearbox with oil, checking the oil level using the control plug on the side. That's all - the clutch disc has been replaced.

Replacing the clutch fork

Replacing the clutch fork on the Gazelle Business model is very easy to do; you do not need to remove the gearbox for this. This type of repair can also be done by yourself.

znanieavto.ru

How to change the clutch on a GAZelle video

March 6, 2013

This article shows in detail on video how to change the clutch on a Gazelle. After watching the video, you will immediately be able to easily replace the clutch yourself, without going to any car service center.

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Repair and replacement of clutch on GAZELLE

The clutch is a special automobile mechanism that is used when starting to move from a standstill to transmit torque from the car engine to the gearbox, and also serves for smooth and comfortable gear shifting in the car.

On domestic cars, and in particular on a GESEL car, repairs and replacement of the clutch are required quite often; this is perhaps one of the weakest components of the car, which is not of high quality, reliability and durability. Despite all this, the life of the clutch on absolutely any car largely depends on the operating conditions of the car.

If any characteristic sounds appear in the GAZELLE clutch, you need to pay attention to this and react as quickly as possible, since such sounds may indicate a clutch failure.

There may be several reasons for replacing the clutch on a GAZelle car.

Advice

One of the most common is the failure of a special clutch bearing.

It turns out that the clutch disk is not clamped at the proper level by the basket and, so to speak, slips; the basket, in turn, does not completely release the disk and it becomes almost impossible or impossible to change gear. In this case, the clutch needs to be replaced.

Professionals from any car service center can easily cope with this problem and repair and replace the clutch on a GAZELLE in a matter of minutes.

However, it is worth knowing that this matter is not particularly complicated and, by following all the actions of the specialists in the video, you can cope with this breakdown yourself without any special knowledge.

To do this, you just need to purchase or prepare a wrench with suitable attachments in order to unscrew the fastening nuts, and, of course, a little free time.

Watch the video:

nind.ru

Removing clutch discs from a Gazelle car

Page 1 of 2

We remove the clutch housing (see article - “Removing the clutch housing”).

We use a core to mark the relative position of the casing and flywheel.

1. While holding the flywheel from turning with a screwdriver or a mounting spatula, a wrench or a 12-point socket, unscrew 6 bolts. 2. Remove the drive disk assembly (basket) and the driven disk.

After disassembling, the clutch parts should be washed in kerosene and inspected. Cracks, burrs and deep grooves are not allowed on the surface of the drive discs. If present, replace the flywheel and basket assembly.

We replace the driven disk with linings worn to the rivets, warped, cracked, oiled and burnt. The protrusion of the ends of the diaphragm spring petals is controlled using a spacer.

When moving the ends of the petals 8.5 mm down, the pressure plate offset must be at least 1.3 mm, otherwise we replace the drive disk (basket) assembly.

note

Any cracks or breaks are not allowed on the crankcase. During assembly, we coat the rubbing surfaces of the fork, coupling, pushers and shaft splines with CV joint-4 lubricant.

Install the disks in the following sequence

1. Insert the centering mandrel into the engine flywheel bearing. 2. We put the driven disk on it.

3. On one side the disc hub protrudes less than on the other. This side should be facing the flywheel. 4. Place the basket on the flywheel and secure it with 6 bolts (the holes match only in one position). After tightening the bolts, remove the mandrel.

Dismantling the clutch of a car with an engine model ZMZ-402

We carry out the work in an inspection ditch.

We remove the gearbox.

autoruk.ru

Spring-lever clutch

According to the principle of operation and design of most parts, a spring-lever clutch is similar to a diaphragm clutch.

The main difference is in the design of the drive disk (basket), which consists of a pressure disk casing, clutch release levers and pressure springs.

The design of the drive plate ensures the transmission of torque through the clutch housing, as well as the centering of the pressure plate and its axial movement when the clutch is disengaged.

The pressure plate is made with three protrusions, in the grooves of which the clutch release levers are installed on the axles.

The levers are connected to the clutch housing by support forks.

Spherical nuts are screwed onto the threaded parts of the forks.

The shanks of the support forks are countersunk to prevent the nuts from loosening.

The nuts are pressed against the spherical surfaces of the casing by conical springs.

The hinged mounting of the support forks compensates for changes in the radial distance between the axes of the levers when the clutch is disengaged, and also allows the ends of the levers to self-align.

The lever axes have needle bearings.

The clutch housing has three rectangular holes for the pressure plate protrusions.

The housing is attached to the flywheel with six bolts.

Under the casing there are nine pairs of cylindrical compression springs.