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Updated transmission with cable drive. How to install a manual transmission with a cable drive

Engineers of AvtoVAZ fulfill their promises. Recently, a new gearbox with a VAZ-2181 index appeared. This transmission is now installed on all modifications of the "Lada". This is the "Grant", "Priora", "Kalina", as well as "Vesta". The new transmission with cable drive has its own characteristics and a lot of advantages over traditional designs.

How did you create the transmission?

At the heart of the new CAT system is the old design, which is familiar to many more by VAZ-2108. Naturally, the engineers made minor improvements. Weak points in this box are also well known to all owners of VAZ cars. So, among the weak points, many people have difficulty in switching gears, large strokes of the shift lever, a rather blurred switching scheme, and vibrations during operation. The developers decided not to change the existing gear unit. These are shafts, gears and synchronizers. All refinements require serious financial costs, without which you simply can not do with the launch of a new checkpoint in the series. To ensure the proper quality of meshing gears and synchronization work, you need accurate equipment and a lot of time. The solution was quickly found. Changed the drive and instead of traction there was a "new-old" gearbox with a cable drive.

What changed?

There are changes, albeit insignificant. The volume of oil that has been poured into the new transmission has changed. Compared with the CPR of past designs, it fell by a third. In the serial versions, the engineers decided to switch from mineral oil to semi-synthetic oil. It confidently retains its properties right up to minus 42 degrees Celsius. This is very important only for a new transmission with a cable drive. The oil now does not need to be replaced during the entire life of the car. The box became unattended, as on foreign cars.

Synchronizers

The engineers left the gearbox part practically unchanged. The first and second gear failed to do without multi-cone synchronizers. This is a necessity for the sake of increasing reliability. The second gear experiences the maximum load, and such a synchronizer can prolong the life mechanism. Also, this innovation has significantly reduced the effort at switching. Transmission with a cable drive will be installed in tandem with powerful motors. Therefore, it was necessary to use a larger diameter clutch - 215 mm, which is characterized by an increased moment of inertia. This is the case with the use of a multi-cone synchronizer in the design. The installation of more powerful clutch discs also required the alteration of the crankcase. With the old element, you could install only a 200 mm clutch disc, not more.

What else has changed?

Also moved and starter. Now it is not parallel to the transmission, but along the motor. The very first lots were installed with three-cone synchronizers. However, after the calculations it became clear that biconical is not worse, and their cost is cheaper and they can withstand the required torque (even with a margin). In addition, these synchronizers allowed to remove the problem cone on the gears of the first and second gears. Previously, it was in contact with the synchronizer ring and required high accuracy in manufacturing. Now a set of rings creates two friction surfaces. This improved the synchronization process, made it softer and more efficient. To make the switching process easier, the gearbox with a rope drive from AvtoVAZ received synchronizers with a reduced angle of the bevel of the teeth. Also, the force for pre-pressing was reduced.

Switching system

In the old modification of the transmission, the shift mechanism was at the bottom and was constantly lubricated from the oil bath. After the car was at night in the cold, the oil in the checkpoint was dense. Within a few kilometers the transmissions were switched on with difficulty. In addition, at the bottom of the gearbox were rod locks and forks for reverse switching, switches for reversing lamps and an oil seal for gear selection. All these elements were potential places for smudges of oil. This problem could be solved with the help of various sealants and other means, but no radical solution was invented. It was necessary to move the mechanism up. The upgraded MKPP with a cable drive is equipped with a different switching system. Now it is a separate module. It can be installed in the last place and dismantled without having to parse the box. This is a very technological move, which will be appreciated by motorists. When the concept of the new box was still being developed, the engineers made a selector grating that clearly repeated the switching pattern and set the selector stroke when selecting the desired gear. The cable transmission also has a lock. Now you can not turn on the back gear even deliberately. It appears only after the selector is moved to the neutral position.

Made with German precision

When this concept was transferred from paper to a real exhibit, and the mechanism began to work correctly, the module went to Germany, to the firm "Scheffler". The Germans brought the knot to mind. The company has long been engaged in the development of various transmission systems, makes engines. German specialists carefully looked at the development of Russian engineers and suggested the following. Use a three-dimensional central plate instead of a system of return springs with locks will be more reasonable. The special spatial shape of this plate was calculated with the help of computer programs, and was manufactured using high-precision equipment. This accuracy is due to the fact that a special ball of the latch moves along the plate. And it is the plate that regulates the forces when selecting and switching gears. Characteristics, which will have a new cable transmission, were selected with the help of a simulation stand. The man sat down on the chair and turned on various programs. Automatic systems mimic the switching circuits, the forces on the lever and its strokes. And so, in small steps, the Germans were able to choose the optimal settings. With the help of a computer, parameters and a mathematical model were chosen, on which these plates will then be made.

Rope drive

At AvtoVAZ from the traction drive decided to abandon the whole, even despite the maximum simplicity and cheapness of the system. Almost all motor-car manufacturers have already abandoned traction. The gearbox with a cable drive was first introduced as an experiment even at Samara. Then the components were purchased from Morse. However, that KPP had a lower location of the switching mechanism, which made the use of cables rather problematic, scare the engineers and cost. The project was not closed, and the serial updated box with a cable drive appeared only recently. The use of cables significantly facilitated the switching process and made it more precise. Also, the vibrations decreased and the backlash decreased. What is interesting: in the clutch mechanism, they wanted to remove the cable, and in its place to install a hydraulic system. However, based on economic considerations, he remained. But the hydraulic drive works more clearly. There are advantages with respect to the layout - tubes and hoses are much easier to lay. The cable for the new gearbox had to be made longer, and this unnecessary mechanical loss and with them an additional effort that must be applied to the pedal. As a result, the information activity of the clutch is much worse.

How does the new PPC work?

To feel all the benefits of this transmission, you need to try it yourself, how to turn on the checkpoint on the "Kalina" with a cable drive. It works quite differently. Already many owners of cars with this type of drive noted that everything works very clearly, and the switching process does not require any effort. They also note the complete absence of vibrations. In movements of the selector nothing has changed. However, now he does not hang out, but only quietly clicks - there are no backlashes in the new drive. Several times, too, the efforts that must be made to switch gears have decreased. But still there is one minor disadvantage. In order to include the fifth speed, you have to drag on. The rear gear does not always turn on completely. But in general, you can safely say that the cable drive control mechanism of switching boxes - this is what the domestic cars lacked so much. It was possible many times to raise the comfort of using the gearbox and reduce vibration.

Installation of a transmission with a cable drive

The installation process involves some difficulties, but there is nothing supernatural here. It is important to assemble a complete set of all parts and assemblies. In the engine board, it is necessary to make holes in which the cable will pass. From the engine compartment, this place is located next to the heat shield of the steering rack. In the car everything will rise without any alteration. On some models, you need to lower the electronic control unit. Also it is necessary to file a little a tunnel. During installation, the cables must not be bent. The upper part between the engine and the clutch housing is perfect, but the lower one will have to be modified. You can take it from an ordinary box. For those who do not know how to install a manual transmission with a cable drive, it is better to order this service in the service station. At a cost this will result in 10 thousand rubles.

Maintenance of cable transmission

Those motorists who were lucky to own such a checkpoint are very pleased with the improvements. But there are a lot of other pluses. You no longer need to adjust the wings. Also, you do not need to change the oil every 60 thousand. The box is very reliable and compact. Oil leakage is now possible only through the oil seals. The only thing that is required for operation is the replacement of the transmission cables of the gearbox control. But the replacement process is not difficult - it is easily performed independently in garage conditions.

Perspective of development

The cable drive has already proved that it is better than all other constructive solutions. Owners of cars where such a transmission was installed, initially were suspicious of her. But its high performance has dispelled all doubts. Engineers of AvtoVAZ also consider this development promising and will develop the idea further.

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