Clutch basket UAZ 402 engine: how to diagnose and replace yourself

Engine. UAZ-402 - legendary power unit, which was installed on many models Ulyanovsk Automobile Plantincluding UAZ-469, UAZ-3151 and UAZ "Lounce"Despite its reliability, the clutch in these cars is one of the most vulnerable nodes, especially when it comes to the problem of the car. clutch-basketWear of this element leads to slippages, jerks during gear shifts and even complete loss of traction. In this article, we will discuss how to determine the malfunction of the basket, which models are suitable for the use of the system. UAZ-402How to make a replacement yourself without mistakes.

Feature Uazov Clutch baskets are compatible with different types of slave discs and squeezable bearings. However, not all parts are equally good: cheap counterparts often fail after 20-30,000 km, while original or quality substitutes for the wheels are not the same. LUK, Sachs or Valeo They last 2-3 times longer, and we analyzed the feedback from the owners and the technical data to give you a clear guide, from diagnostics to the installation of a new cart.

Signs of malfunction of the clutch basket at UAZ 402

Clutch basket (also known as press-plate) rarely fails suddenly - usually the problem grows gradually. Here are the key symptoms that should alert you:

• 🔥 Clutch slip The engine is roaring, but the car is not accelerating, especially when climbing or when starting abruptly, which means that the basket does not create enough pressure on the driven disk.
• ⚡ Twisting on the actuation of the clutch - you feel the jolts when you move from a place or shift gears. Often the worn petals of the diaphragm spring are to blame.
• 🔊 Extraneous sounds - grinding, knocking or whistling when pressed on the clutch pedal, may indicate the collapse of the squeezing bearing or deformation of the basket.
• 🛑 Tight or "cotton" pedal press If the pedal became harder to press or, conversely, fails without resistance, the problem may be in the diaphragm spring of the basket.

It is important to distinguish the faulty basket from the problems with drive-by or squeezable bearingFor example, if the clutch is leading (not completely shutting down), it is often the drive drive that is to blame, not the basket, and accurate diagnosis requires removal of the transmission, but there are indirect methods of verification.

One of the simplest tests is check-in:

1. Accelerate to 40-50 km / h in 3rd gear.
2. Press the gas sharply. If the speed increases and the speed does not, the clutch stalls.
3. Try to get out of position in 4th gear, and if the engine doesn't stop, the basket doesn't make the right pin.

⚠️ Attention: If you ignore the clutch slip, it will lead to overheating and deformation of the flywheel. In advanced cases, you will need to replace the flywheel, which is 2-3 times more expensive than timely repair of the basket.

Which clutch basket to choose for UAZ 402: original vs analogues

There are more than 10 options on the market for clutch baskets UAZ-402But they're not all equally reliable. ouaz articulate 402-1601180But the quality of the product varies by batch, with good and defective ones, and alternatives from European brands are often better in resource, but also more expensive.

Brand	Articulum	Average price (ruble)	Resource (thousands of km)	Features
UAZ (original)	402-1601180	3 500–4 200	50–80	Suitable for a regular checkpoint, but the quality varies
LUK	620 3101 10	5 800–6 500	100–120	Best Price-Quality Relationship, Soft Inclusion
Sachs	3000 951 009	7 200–8 000	120–150	Hard spring, suitable for severe conditions
Valeo	826 577	6 500–7 300	90–110	Quiet work, but sensitive to overheating
CCATE (Russia)	402-1601180-10	2 800–3 500	30–60	Budget option, often marriage occurs

When choosing a basket, pay attention to:

• 🔧 Type of diaphragm spring - UAZ-402 18-petal spring baskets are suitable. 12-petal (from the GAZ-24) will not provide the desired clamping.
• 📏 Diameter. - must be 225 mm (standard for UAZ-402240 mm baskets (from ZMZ-406) will not be suitable without further development.
• 🔄 Compatibility with the squeezable bearing Some baskets require the bearing to be replaced with a model with a different landing size.

Step by step replacement of the clutch basket on UAZ 402

Replacement of the clutch basket by UAZ-402 It requires the gearbox to be removed, so you can't do without a hole or a lift, and it takes 4-6 hours on average (excluding the time to remove/install the gearbox).

Pour oil from the gearbox |Disconnect the drive shaft |Remove the working clutch cylinder |Untuck the gearbox mount bolts to the engine (6 pcs) |Hang the gearbox on the tal or point-->

Step 1: Dismantling the old basket

1. After removing the gearbox, mark the position of the flywheel relative to the crankshaft with a marker - this will help to maintain balance during the reverse assembly.
2. Unscrew the 6 bolts of the basket attachment to the flywheel (head on 13). Bolts are better to twist the cross to avoid deformation.
3. Take the basket off with the drive. Check the flywheel for cracks, bullies, or uneven wear.

Step 2: Installation of a new basket

1. Before installing a new basket, clean the flywheel surface of the oil and dirt. solvent 646 or white-spirit.
2. Install the driven disk in the basket so that the heavier part (with damper springs) was directed towards the flywheel.
3. Fix the basket on the flywheel, twisting the bolts in 2-3 approaches with a force of 25-30 N·m. Do not use a pneumatic tool - the pulling of bolts leads to deformation of the diaphragm spring!

Step 3: Centering the driven disk

This is the most important step, without the centering, the clutch will hit when you turn it on.

1. Insert a mandrel into the driven disk (you can use the old primary shaft of the gearbox).
2. Adjust the position of the disc so that the mandrel enters the crankshaft bearing without backlash.
3. Secure the basket permanently and make sure that the disk is not clamped and rotates freely.

⚠️ Attention: If after replacing the basket, the clutch pedal became "cotton" or too tight, check the gap between the squeezable bearing and the spring petals. It should be 2-3 mm. If necessary, adjust the pusher of the working cylinder.

Tuning clutch baskets: when it is justified

Standard clutch basket UAZ-402 It's designed to have a torque of up to 180 Nm, but if you're planning to tune the engine (for example, installing a turbine or increasing the displacement), it may not be enough.

• 🔥 Reinforced baskets - for example, from Sachs Performance or SpecThey can withstand up to 250 Nm, but require further development of the clutch drive.
• 🔄 Baskets with ceramic drive - Suitable for extreme loads (competitions, off-road), but quickly wear out the flywheel.
• ⚙️ Double-plate clutches - used in racing uazahBut they need to modify the bell.

Before tuning the basket, consider:

• The reinforced basket increases the load on squeezer You will also have to change it to a stronger one.
• Ceramic discs do not tolerate slippers in the city - they are designed for short-term high loads.
• Two-plate clutches require adjustment of the free pedal, otherwise there will be an incomplete shutdown.

What happens if you put a basket from ZMZ-406 on UAZ-402?

Basket from ZMZ-406 (article) 406-1601180) is similar in appearance but has a different diameter (240 mm instead of 225 mm) and a different spring stiffness. UAZ-402 It can only be modified:

1. Replacement of the flywheel with the model from ZMZ-406 (article) 406-1005080).

2. Modification of the bell of the checkpoint to a larger diameter.

3. Replacement of the slave disc and the squeeze bearing.

Without these improvements, the clutch will slip or not completely shut down.

Common mistakes when replacing the clutch basket

Even experienced mechanics sometimes make mistakes that lead to a quick failure of the basket.

1. Use of an old slave disk If the disk has cracks or wear of friction linings more than 0.5 mm, it must be replaced. A new basket with a worn disk will last 2-3 times less.
2. Wrong tightening of basket bolts If you twist them in a circle (rather than cross-cross), the diaphragm spring will deform, which will lead to uneven pressing and jerking.
3. Lack of centering of the driven disk - without a mandrel, the disk will be curved, which will cause vibrations and accelerated wear.
4. Ignoring the flywheel condition - if the flywheel has deep furrows or cracks, a new basket "eat" for 5-10 thousand km In such cases, the flywheel must be drilled or replaced.
5. Failure to observe the puffing moment - bolts of the basket should be tightened with a force of 25-30 N·m. The retraction leads to breakage of the spring petals, the undertightness - to slippage.

Another typical problem is spare-part incompatibilityFor example, if you put a basket. LUK narcissistic 620 3101 10And the old one was left behind. ouaz), then because of the different drive stroke, the clutch will "lead." Always check the compatibility by catalog:

Clutch basket	Suitable squeezing bearing	Note
UAZ original (402-1601180)	ouaz (402-1601190)	Staff kit, but bearing often fails first
LUK (620 3101 10)	LUK (500 0211 10)	Requires adjustment of the free running of the pedal
Sachs (3000 951 009)	Sachs (3000 951 010)	The bearing comes complete with a basket

Adjustment of clutch after basket replacement

After installing a new basket, be sure to adjust free-clutchFor UAZ-402 It should be 25-35 mm. adjustment is made by changing the length of the pusher of the working cylinder:

1. Reduce the counternut on the pusher (key on 13).
2. Rotate the pusher until the gap between the fork and the squeeze bearing is 2-3 mm.
3. Tighten the counternut and check the pedal - it should be pressed smoothly, without dips.

If the pedal is too tight, there are two possible reasons:

• 🔧 Clutch cable pulled over. (on models with mechanical drive).
• 🔄 Defect of the diaphragm spring basket If the spring is too rigid, it will have to be replaced.

To check the adjustment:

1. Start the engine and turn on gear 1.
2. Smoothly release the clutch pedal. The car should start when the pedal passes 2/3 of the move.
3. If the clutch is "sufficient" at the very beginning or end of the turn - adjust the pusher again.

⚠️ Attention: Nana UAZ-402 With a hydraulic clutch drive after adjustment, be sure to pump the system to remove air. Otherwise, the pedal will be "cotton", and the clutch will not completely turn off.

The service life of the clutch basket: how to extend the resource

Average life of the clutch basket on UAZ-402 It is 80-120 thousand km, but with proper operation, this figure can be increased to 150-180 thousand km.

• 🚗 Avoid slippage. - prolonged retention of the clutch pedal in a semi-pressed state (for example, in traffic jams) leads to overheating and deformation of the spring petals.
• 🔧 Check your fluid levels regularly A drop in the level indicates a leak that could cause the basket to fail.
• 🛑 Do not use the clutch as a brake. sharp pedal throws when braking the engine accelerate the wear of friction linings and springs.
• 🔄 Change the oil at the checkpoint every 50,000 km dirty oil worsens the heat sink from the basket, which reduces its resource.

Also pay attention to spare-part quality:

• Cheap baskets from ZATE or unknown brands often have uneven stiffness of petals, which leads to jerks.
• Fakes under LUK or Sachs It can be identified by the absence of holograms on the packaging and rough processing of metal.
• Driveable asbestos pads are cheaper, but they wear the basket and flywheel faster, with ceramic or organic pads being the best choice.

FAQ: Frequent questions about the clutch basket UAZ 402

Can I drive with a clutch basket?

Short-term, yes, but this leads to accelerated wear of the flywheel and the drive. If the basket slips more than 5-7 days, the flywheel can deform and have to be changed (the cost of a new flywheel is from 8 000 rubles.). In addition, slipping increases fuel consumption by 10-15% due to power losses.

Which drive is better to put with a basket LUK 620 3101 10?

For this basket, slave disks are optimally suitable:

• LUK 620 3001 10 (organic overlays, soft inclusion);
• Sachs 1880 003 037 (Ceramic overlays, for severe conditions);
• Valeo 826 576 (Universal version, medium resource).

It is not recommended to put discs from ouaz (402-1601130) - they are thinner and wear out faster.

What if the clutch pedal became too tight after replacing the basket?

There may be several reasons:

1. The diaphragm spring of the basket is pulled (often with a pneumatic tool) and the solution is to replace the basket.
2. Incompatibility of the squeezable bearing with the new basket, the solution is to install the bearing of the same brand as the basket.
3. The solution is to jam the cable (power drive) or the working cylinder (hydraulic) and the solution is to lubricate the cable or pump the hydraulic drive.

If the problem remains, check the free pedal - it should be 25-35 mm.

Can I use a flywheel instead of a replacement when installing a new basket?

Yes, if the furrow depth on the flywheel is less than 0.5 mm, and the flywheel itself has no cracks, the duct is performed on the lathe with balance. The cost of the service is about 1,500-2000 rubles. If the furrows are deeper or the flywheel "led" from overheating, it must be replaced (article of the original - 402-1005080).

what oil to use in the gearbox after replacing the clutch basket?

For the checkpoint UAZ-402 Recommended oils:

• Mineral: TAD-17I (GOST 23652-79) or TM-5-18 (for cold climates).
• Semi-intynthetics: Lukoil TM-5 85W-90 (GL-5) is the best option for most regions.
• Synthetics: Castrol Syntrax Universal Plus 75W-90 - for extreme loads (off-road, towing).

The volume of oil is 1.6 liters. It must be changed every 50 thousand km or once every 2 years.