Automobiles, Cars
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.
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.
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.
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.
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.
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.
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.
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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