How to properly install the clutch fork on a gazelle

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Replacing the Gazelle 406 Clutch Fork

Adjusting and replacing the clutch on a Gazelle
Replacing the working or head cylinder of the clutch on a Gazelle, as well as other parts, can prevent car failure. It is important to diagnose and repair the vehicle in a timely manner, and replace the clutch kit and other components as needed. In the future, this will help avoid breakdowns on the highway and accidents.

Clutch diagram for Gazelle

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 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.

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

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...

How to make a quality replacement

Carrying out minor repairs, replacing the clutch fork, including adjusting its pedal, will not require much time. If there are high-quality parts, for example, made by Sachs or Kraft, the replacement will only take about 2 hours.

The Gazelle clutch requires proper handling and timely replacement as a result of frequent repairs and adjustments. Replacing the entire assembly is not necessary in every case. The stages of replacement depend on the brand of Gazelle car, determined by the engine, for example, Cummins ZMZ 406 and 405, etc.

The clutch kit must include a fork, a disc, a hydraulic hose, a hydraulic clutch, a clutch basket, a release bearing, the price of which from the manufacturer is lower than the cost of parts offered by chain stores. After diagnostics, it may be necessary to replace only the clutch slave cylinder, which operates under fairly high loads. In some cases, it is necessary to solve the problem with changing the gearbox, discovered as a result of system diagnostics.

Sometimes it may be necessary to check the entire pipeline and also bleed the system. The cause of the violation may be damage to the reservoir included in the Gazelle clutch kit.

Causes of clutch failure

Replacing the clutch may be necessary as a result of intensive use of the Gazelle car and if the following errors occur:

The process of replacing the clutch on a Gazelle

1. Low quality parts were used during assembly.
2. The clutch pedal was kept depressed while driving, which is strictly prohibited by the manufacturers.
3. There were jerks from a standstill at high speeds.

To increase the service life of the Gazelle clutch, installation of parts manufactured by the manufacturing company Sachs will be reliable. They are recommended by the manufacturer because they are reliable and have been tested for installation compatibility with the transmission and engine. Under the same conditions clutch , unlike parts from other manufacturers, will last longer. A common analogue of the Gazelle Business clutch, produced by Kraft, is not only of good quality, but also has a fairly low defect rate. The most common reasons why Gazelle owners contact service departments are malfunctions related to the clutch release drive.

Among the main problems are:

• leak of the Gazelle clutch master cylinder (MCC);
• removal of brake fluid from the hydraulic fluid reservoir;
• Clutch slave cylinder (CLC) leak;
• bypass of the cuff of the central nervous system;
• bent or fallen out working cylinder rod, etc.

Careful operation of the car does not imply any jerks, but only the presence of conditions that allow you to move off smoothly and change gears while the car is moving. Most often, replacement is required for trucks. A Gazelle car intended for business requires increased attention to this unit, the elimination of breakdowns in which is often not possible. Since replacing the device does not require removing the motor, you can repair the clutch or install new parts yourself.

Diagnostic principle and clutch replacement rules

Incorrect operation of the clutch system is determined by the following main points:

• noise is heard in the gearbox when the car is moving;
• the transmission turns off spontaneously;
• changing gears causes various extraneous noises;
• Changing gears is difficult.

Node improvement

In order to bleed the clutch system, you will have to completely remove all the old parts of the assembly. The factory design itself is unreliable, so you shouldn’t hope that replacing 1-2 elements will change anything. If you don’t want to spend a long time with repairing the Gazelle, then replace everything at once.

It is not recommended to use structural elements from one GAZelle model to another. For example, the clutch basket from 406 is also suitable for 402 gazelle, but during operation there are difficulties with switching to 5th gear and reverse gear.

Experimentation is not recommended. It is best to carry out replacement at a trusted car service center. It is worth finding out about the quality of the service in advance, because if something is installed incorrectly, you will have to redo it. You can install the components and the entire assembly yourself, but this will require a platform or several jacks, which not every driver has.

1. Disconnect the pusher from the clutch pedal in the passenger compartment by unscrewing nut 1 and removing the pusher axle 2 with two plastic bushings.

Disconnect return spring 5 from the pedal.

Remove cotter pin 3, unscrew nut 4 securing the pedal to the axle and remove the pedal assembly with two bushings.

2. If necessary, remove the pedal pad cover.

Inspection and troubleshooting of clutch pedal parts

1. Bushings must not have mechanical damage. One-sided wear of the bushings indicates that there is unacceptable play in the pedal assembly, which in turn affects the full travel of the pedal.

Replace defective parts.

2. If the return spring has lost its elasticity, i.e. When the clutch pedal is free, it does not reach the limiter; replace the spring.

3. If there is significant wear on the pattern of the clutch pedal pad, it is recommended to replace it.

Installation

Install the clutch pedal in the reverse order of removal. In this case, it is necessary to lubricate the friction surfaces of the bushings and axle with a thin layer of graphite lubricant.

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.

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.

see also

Comments 13

I see, I'll try it, thanks everyone

The only thing I would remove is the clutch tray to check, otherwise the bearing may turn and not stand on its feet and the spring on the fork may not get to the soldier. I removed it from the donor, and this spring was like one tendril between the fork and the soldier.

yes, there seems to be nothing complicated. The only thing I remember is that the boot bolt was broken off; I had to tinker with it because... not convenient. I don’t really remember how I inserted it, I just found some angle and put it on the (so to speak) ball joint

Yes, essentially nothing complicated, it hangs on the “frame” of the boot. www.autoprospect.ru/gaz/3…lga/images/03-clutch2.jpg You press the piston so that it does not rest, carefully pull it off the hinge and pull it out, reassemble it in the reverse order, changing worn parts such as a plastic bushing, a torn boot and etc. car-exotic.com/gaz-cars/g…-31105-auto-clutch-6.html or so, in words automn.ru/gaz-3110/gaz-35…m_id-3292.m_id2-4511. html

no pitfalls no there is a sub-machine topic for 3 minutes!

How to make a quality replacement

Carrying out minor repairs, replacing the clutch fork, including adjusting its pedal, will not require much time. If there are high-quality parts, for example, made by Sachs or Kraft, the replacement will only take about 2 hours.

The Gazelle clutch requires proper handling and timely replacement as a result of frequent repairs and adjustments. Replacing the entire assembly is not necessary in every case. The stages of replacement depend on the brand of Gazelle car, determined by the engine, for example, Cummins ZMZ 406 and 405, etc.

The clutch kit must include a fork, a disc, a hydraulic hose, a hydraulic clutch, a clutch basket, a release bearing, the price of which from the manufacturer is lower than the cost of parts offered by chain stores. After diagnostics, it may be necessary to replace only the clutch slave cylinder, which operates under fairly high loads. In some cases, it is necessary to solve the problem with changing the gearbox, discovered as a result of system diagnostics.

Sometimes it may be necessary to check the entire pipeline and also bleed the system. The cause of the violation may be damage to the reservoir included in the Gazelle clutch kit.

Causes of clutch failure

Replacing the clutch may be necessary as a result of intensive use of the Gazelle car and if the following errors occur:

The process of replacing the clutch on a Gazelle

1. Low quality parts were used during assembly.
2. The clutch pedal was kept depressed while driving, which is strictly prohibited by the manufacturers.
3. There were jerks from a standstill at high speeds.

To increase the service life of the Gazelle clutch, installation of parts manufactured by the Sachs manufacturing company will be reliable. They are recommended by the manufacturer because they are reliable and have been tested for installation compatibility with the transmission and engine. Under the same conditions, the Sachs clutch, unlike parts from other manufacturers, will last longer. A common analogue of the Gazelle Business clutch, produced by Kraft, is not only of good quality, but also has a fairly low defect rate. The most common reasons why Gazelle owners contact service departments are malfunctions related to the clutch release drive.

Among the main problems are:

• leak of the Gazelle clutch master cylinder (MCC);
• removal of brake fluid from the hydraulic fluid reservoir;
• Clutch slave cylinder (CLC) leak;
• bypass of the cuff of the central nervous system;
• bent or fallen out working cylinder rod, etc.

Careful operation of the car does not imply any jerks, but only the presence of conditions that allow you to move off smoothly and change gears while the car is moving. Most often, clutch replacement is required for trucks. A Gazelle car intended for business requires increased attention to this unit, the elimination of breakdowns in which is often not possible. Since replacing the device does not require removing the motor, you can repair the clutch or install new parts yourself.

Diagnostic principle and clutch replacement rules

Incorrect operation of the clutch system is determined by the following main points:

• noise is heard in the gearbox when the car is moving;
• the transmission turns off spontaneously;
• changing gears causes various extraneous noises;
• Changing gears is difficult.

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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 transmission 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 solve these problems, the car has 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.

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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.

The clutch pressure plate, attached to the housing, presses the pushrod against the flywheel. The drive sleeve attached to the input shaft must move freely along it. The hub body is equipped with damping springs, which act as vibration dampers and ensure smooth running.

To apply the necessary pressing force, there is a spring with petals that are released from the bearing. This is the connection between the drive and the clutch on which the fork with the lever is mounted. At its end is attached another lever or cable leading to the clutch pedal.

Replacing the ZMZ-402 clutch fork on the Volga

Early day weekend replaced

I'm
the clutch fork
.

How to replace the clutch fork without removing the gearbox.

as a replacement for the clutch plug

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

How to make a quality replacement

Repairing and replacing the clutch plug, including adjusting the pedal, takes little time. With high quality parts such as those made by Sachs or Kraft, the replacement will only take about 2 hours.

The Gazelle clutch requires proper monitoring and timely replacement due to frequent repairs and adjustments. Replacing the entire assembly is not necessary in every case. The replacement steps depend on the brand of Gazelle car engine, such as Cummins ZMZ 406 and 405 and so on.

You may also like

The clutch kit should include a plug, disc, hydraulic hose, RCC, center line, clutch basket, exhaust bearing, the price of which is lower than the manufacturer's price for spare parts offered by online stores. After diagnostics, it may be necessary to replace only the driven clutch cylinder, which operates under fairly high loads. In some cases, it is necessary to solve the problem of replacing the transmission detected as a result of system diagnostics.

Sometimes it may be necessary to perform a full inspection of the pipeline, as well as bleeding the system. This may be caused by damage to the tank included in the clutch kit on the Gazelle.

Causes of clutch failure

Clutch replacement may be required due to intensive use of the Gazelle vehicle and the following errors:

Gazelle clutch replacement process

1. Low quality parts were used during assembly.
2. While driving, the clutch pedal was held, which is strictly prohibited for manufacturers.
3. The dashes were made from the stage at high speeds.

To increase the service life of the Gazelle clutch, the installation of parts manufactured by Sachs will be reliable. They are recommended by the manufacturer because they are reliable and have been tested for compatibility with the transmission and engine. Under the same conditions, the Sachs clutch, unlike parts from other manufacturers, will last longer. The general analogue of the Gazelle Business clutch produced by Kraft is not only good quality, but also a fairly low deflection coefficient. The most common reasons why Gazelle owners contact them for service are faults related to the clutch release.

Replacing the clutch fork yourself

• Replacing the clutch fork yourself
• 1. What is a clutch fork, and what role does it play in the performance of a car’s transmission?
• 2. How to determine the malfunction of the clutch fork and find out the reasons for their occurrence?
• 3. Replacing the clutch fork: what are the features of the work?

The need to replace a car's clutch fork does not arise very often. However, if this seemingly insignificant part fails, the movement of the car is literally paralyzed. After all, the clutch fork is one of the important elements of the transmission, and if it cannot fully perform the functions assigned to it, torque will not be transmitted to the drive wheels from the engine and, as a result, the car will not move. For this reason, even such a minor breakdown must be repaired as quickly as possible. Fortunately, this can be done at home and without the help of specialists.

What is a clutch fork, and what role does it play in the performance of a car's transmission?

Before moving directly to the clutch fork, it would be logical to become familiar with what the clutch mechanism itself is and what role it plays together with its fork in the functioning of the car.

There are several types of clutches that appeared and were modified simultaneously with the development of the automotive industry. Today you can find three types of clutch in cars:

1. Frictional, in which torque from the engine is transmitted to the wheels due to friction. This type, in turn, is divided into single-disc, double-disc and multi-disc friction clutches. Most often found on modern cars.

2. Hydraulic, in which the operation of the elements is ensured by the flow of fluid.

3. Electromagnetic, for the functioning of which a magnetic field is used.

As already mentioned, most modern cars are equipped with a single-plate clutch. Its design includes the following list of elements:

— pressure (drive) and driven disks;

— release bearing and its coupling;

id:14119 Essentially, this type of clutch is constantly in an activated state. Its operation is ensured by a separate drive. The whole operating principle of this mechanism is as follows:

1. When the driver inside the car presses the clutch pedal, it transmits the effect to the clutch drive, which moves the fork of this mechanism.

2. In turn, the fork we are interested in acts on the clutch release bearing. Due to this, the bearing moves slightly and acts on the petals of the diaphragm spring of the pressure plate.

3. As a result, the spring petals bend towards the flywheel, and its outer edge moves away from the pressure plate, thereby giving it freedom. At the same time, the “pressing” of the pressure plate occurs thanks to tangential springs.

4. As a result, torque transmission stops.

5. When the driver releases the clutch pedal again, by triggering the diaphragm spring, the pressure and driven disks are closed back together, and the spring also establishes contact with the flywheel. The transmission of torque to the gearbox is restored.

From this description of the process of functioning of the clutch mechanism, the operation of its fork becomes quite clear.
This part plays the most important role in turning the clutch on and off between the engine and transmission, that is, creating free space between the pressure and driven disks.
This is necessary in order to completely disconnect the gearbox from the car engine.

If we are talking about a manual gearbox, then its operation becomes completely impossible without a working clutch fork. In particular, thanks to her:

1. The entire multi-structure gear shift mechanism of the vehicle is started.

2. The car can remain stationary even with the engine running and without engaging neutral.

3. The vehicle's maneuverability increases when driving at low speeds.

We can summarize that without the fork, the clutch mechanism cannot function, since this part is a switch and switch. Thanks to it, the driver can control the operation of the engine and provide it with optimal operating modes.

How to determine the malfunction of the clutch fork and find out the reasons for their occurrence?

If the car’s clutch begins to work unsatisfactorily and respond poorly to pedal pressure, most likely a breakdown has occurred in one of its mechanisms, and most likely it is the fork. In order to somehow eliminate such a malfunction, some car enthusiasts manage to carry out the so-called free play adjustment of the fork. Thanks to this, normal operation of the clutch is restored for some time, but such a procedure is usually not enough for a long time, and malfunctions in the clutch continue to appear.

Messages [1 to 25 of 44]

1 Topic from Chinavod 11/26/2013 12:30:07

• Chinavod
• Participant
• Inactive

• From: Krasnodar village
• Registered: 24.08.2012
• Messages: 1251

Topic: Clutch fork bends.

Hello everyone! Actually, the question is on topic. What kind of shit is it made of? I'm changing it for the third time in three months. It could be strengthened somehow, or it might be more durable from another car. Anyone who has experimented, please tell me.

There is oppression in the same place (pictured):

2 Reply from Hi Com 11/26/2013 12:32:20

• Hi Com
• Participant
• Inactive

• From: Krasnodar
• Registered: 28.09.2009
• Messages: 9284

Re: Clutch fork bends.

Chinavod , the problem is not with the plug.

3 Reply from Chinavod 11/26/2013 12:36:21

• Chinavod
• Participant
• Inactive

• From: Krasnodar village
• Registered: 24.08.2012
• Messages: 1251

Re: Clutch fork bends.

What then if this fork is easy to bend? I buy factory ones.

4 Reply from Hi Com 11/26/2013 12:38:44 PM

• Hi Com
• Participant
• Inactive

• From: Krasnodar
• Registered: 28.09.2009
• Messages: 9284

Re: Clutch fork bends.

Chinavod , in a basket or wedged on a release guide.

5 Reply from SHERIF 11/26/2013 12:39:17

• SHERIF
• Participant
• Inactive

• From: Krasnodar (Severny village)
• Registered: 18.10.2011
• Messages: 379

Re: Clutch fork bends.

Chinavod , the problem is not with the plug.

This disc is definitely already hooked (but it can be strengthened by welding square reinforcement inside)

6 Reply from 300300 11/26/2013 12:41:52

• 300300
• Participant
• Inactive

• From: Krasnodar
• Registered: 13.08.2013
• Messages: 1543

Re: Clutch fork bends.

If the fork bends more than once, you need to change the clutch.

7 Reply from Chinavod 11/26/2013 12:54:45

• Chinavod
• Participant
• Inactive

• From: Krasnodar village
• Registered: 24.08.2012
• Messages: 1251

Re: Clutch fork bends.

The clutch disc is still alive (I looked when I removed the casing). The release lever does not jam, as it works smoothly and effortlessly. Therefore, I’m sinning with a fork. The basket, however, is reinforced.

How to strengthen the fork? Are there any photos of experiments on “tuning” the fork? I heard they put a fork on the GAZ-53. Will it work or is it all a joke?

8 Reply from Hi Com 11/26/2013 12:59:58 PM

• Hi Com
• Participant
• Inactive

• From: Krasnodar
• Registered: 28.09.2009
• Messages: 9284

Re: Clutch fork bends.

Well, what does the fork have to do with it?

(but you can strengthen it by welding square reinforcement inside)

9 Reply from Hi Com 11/26/2013 1:27:34 PM

• Hi Com
• Participant
• Inactive

• From: Krasnodar
• Registered: 28.09.2009
• Messages: 9284

Re: Clutch fork bends.

Dark or orange packaging.

10 Reply from Vaha 11/26/2013 13:31:36

• Vaha
• Participant
• Active

• From: capital of Khadyzhen beer
• Registered: 29.06.2011
• Messages: 6588

Re: Clutch fork bends.

Chinavod , did you squat with a barbell? soccer player? Not?

+100 to welding of stiffeners

11 Reply from Ivanovich 11/26/2013 13:39:33

• Ivanovich
• Participant
• Inactive

• From: Krasnodar
• Registered: 26.09.2007
• Messages: 5465

Re: Clutch fork bends.

Make an original plug, label it “reinforced” and forget about the problem. Well, in the sense of selling the UAZ and buying an SUV.