Replacement and repair of the AMT clutch actuator on LADA

06 September 2017 Lada.Online 82 516 13

The main distinguishing feature of an automated transmission (AMT or “robot”) from a mechanical one is the electric actuators produced by ZF, which change gears at the command of the electronic “brains”. The manufacturer claims that the actuator unit is maintenance-free and cannot be repaired, but craftsmen have found a way to repair it with their own hands.

If the car’s warranty has already expired, then replacing the clutch release mechanism actuator yourself will cost tens of thousands of rubles (article numbers: 21820160901200 and 21820170501200). In an attempt to save money, you can try to repair it.

Replacement and repair of the AMT clutch actuator on LADA

Problem

As a rule, car owners are faced with a situation where the actuator begins to creak, which is especially common in hot weather. This component is responsible for pressing the clutch fork. However, it is not difficult to independently eliminate the creaking of the AMT actuator of Lada Vesta and X-Ray. To do this, simply lubricate it.

Vesta's AMT is equipped with actuators from the German company ZF, which has made the unit maintenance-free. However, this limitation can be circumvented. It is worth noting that the service station also offers this service. The price varies between 2,000 rubles.

Replacing the AMT clutch actuator

How to remove the actuator

Disconnect the negative terminal of the battery.
The engine air filter has been removed.
Remove the screw securing the wiring harness.
Remove the three screws securing the AMT actuator unit.

All that remains is to disconnect the connector and pull out the actuator through the top.

Installation

in reverse order.

How to remove the clutch actuator with your own hands from a Lada Vesta car

Dismantling work is carried out in the engine compartment. In order to gain access to the clutch actuator mount, first of all we remove the air filter, to do this we disconnect the pipes from the filter housing and unscrew the two mounting bolts, after which we remove the air filter to the side.

After removing the filter housing, we proceed to directly dismantling the clutch actuator; to do this, unscrew the fastening bolt of the wire block (the location is indicated by the arrow in the photo above).

Now unscrew the three bolts securing the actuator unit, the location of the bolts is indicated in the photo above.
After unscrewing the bolts, remove the clutch actuator by pulling it up, after first disconnecting the cable block. We unscrew the body of the assembly, at this stage there should be no difficulties; after disassembling it we see the following picture:

Carefully inspect the working surfaces of the actuator for possible defects, and if necessary, remove the white compensator.

Plastic parts of the actuator are a sore point of the mechanism. The fact is that they operate at high temperatures and over time the lubricant evaporates, as a result of which the load on the part increases, the plastic does not withstand and cracks, the efficiency of the mechanism decreases, creaks and other extraneous sounds appear. It will not be possible to order such components; they are simply out of stock, but when the problem concerns plastic parts, they can be soldered and the actuator lubricated, which will significantly extend its service life and also eliminate squeaks.

Disassembling the AMT clutch actuator

Unscrew the top cover. We “discharge” the actuator (turn the gear as in the video) and remove the cover (do not open without the clutch load).

Remove the white compensator (Caution! The spring is very powerful!). The thrust rod is simply removed with force.

When assembling, carefully “cock” the mechanism (photo 1 - unloaded, photo 2 - cocked).

There is no need to make any adjustments to the clutch actuator after installation on the vehicle.

AMT clutch actuator repair

Clean the inner surface with solvent. Let's examine the insides. In this example, wear on the ball stops and a crack on the plastic part of the actuator were detected. The problem is that there are no repair kits. That is, AMT clutch actuator parts are not sold separately. If you cannot restore the old ones, all that remains is to lubricate the mechanism.

LIQUI MOLY Thermoflex Spezialfett was used as actuator lubricant. It is very similar to the one that was in the actuator from the factory. Read more about actuator lubrication here.

We perform reassembly and installation of the AMT actuator on the car (see above).

Let us remind you that if other malfunctions occur in the operation of the AMT (howling, crackling, the car jerks, jerking, rattling, etc.), you can determine the cause using these instructions.

Categories of products that may be of interest to you based on the article “Replacement and repair of the AMT clutch actuator on LADA”:

How to lubricate the Lada Vesta clutch actuator and how to do it

Lubrication in the mechanism is necessary to reduce the coefficient of friction of the mating surfaces. The standard consistency gradually dries out and is squeezed out of these places. The same happens with the newly applied composition after 30,000-40,000 km. The operation should be regarded as routine with appropriate frequency.

Where to apply lubricant

The actuator can be in one of two operating states:

Cocked - the purple spring is compressed, the black sector is at the top.
Discharged - the elastic element is relaxed, part of the circle is at the lowest point.

Before applying the lubricant, the white lever must be removed from the housing. It is dismantled in a discharged state.

For your information. It is convenient to move the black sector to one of two positions using an open-end wrench set to “27”. The horn part is located perpendicular to the sector and is inserted into two internal holes. The operation is performed with the body clamped in a vice.

Lubricant is applied to the spherical joints, which are present on the white part and to all its internals. The thrust parts of the spring also need to be lubricated - they are the ones that creak most often. It will not be superfluous to process the release lever, which is located on the clutch fork, and the thrust rod acting on it.

What to lubricate

When choosing a consistency, you should proceed from the operating conditions of the mechanism:

High cyclic loads.
Proximity to sources of thermal radiation.
Critical to cleanliness of parts.
Operability at negative and positive temperatures.

The composition must have stable viscosity over a wide temperature range and be suitable for metal-plastic ball joints. When looking for how to lubricate the clutch actuator on a Lada Vesta, you should focus on the following products:

CIATIM-201 (850 g – 145 rubles).
Total Nevastane XS80 (400 g – 1,200 rubles).
Chevron Ulti-Plex Synthetic Grease EP NLGI 1.5 (400 g - 540 rubles).
Liqui Moly Thermoflex Spezialfett (370 g – 1,600 rubles).

Important! Before installing the drive on the vehicle, the half gear must be placed in the cocked state.

Clutch, gearbox, transmission Lada Vesta

Products from the Dustershop77 range on the topic of the article:

Name	Manufacturer	Price	Availability	Add to cart
DC952-7703062062	Gasket for gearbox drain plug, transfer case Renault Duster / Terrano / Captur original 7703062062	Original	200 / 100 rub. Discount: 50 rub.	5
DC1560-8200884113	Drive oil seal original Renault 8200884113 left	Original	1000 / 800 rub. Discount: 700 rub.	2
DC524-302054100R	Clutch kit for 1.6 (H4M) 4×2 gearbox JR5 (5-speed) original art. 302054100R	Original	8000 / 7400 rub. Discount: 7000 rub.	1
DC1630-7703075180	Filler plug for gearbox / transfer case original 7703075180	Original	200 / 150 rub. Discount: 100 rub.	4
DC1667	Clutch kit Vesta (1.6l 21129 + manual transmission VAZ / AMT) LUK	Analogue	5500 / 4600 rub. Discount: 4400 rub.	2
DC422-510009710	Release bearing H4M 4×2 JR5/JH3 5-speed. LUK 510009710 306200650R 7701478631 8200046103 8200764613 8200990502 306205482R 306205482R 306206219R 306201586R	Analogue	4500 / 3900 rub. Discount: 3500 rub.	2
DC440-8200410813	Drive shaft retaining ring original art. 8200410813	Original	500 / 300 rub. Discount: 250 rub.	3
DC383-ASAM-30799	Gear shift lever bushing ASAM-SA 30799 original art. 7700732903	Analogue	400 / 150 rub. Discount: 100 rub.	1
DC1631-8200201381	Transmission/transfer case filler plug gaskets original 8200201381	Original	500 / 350 rub. Discount: 300 rub.	3
DC956-7700102458	Automatic transmission filter DP2 original 7700102458	Original	900 / 600 rub. Discount: 500 rub.	1
DC950-321031MG0B	Rear gearbox filler plug Renault Duster / Captur / Nissan Terrano 4x4 321031MG0B	Original	1000 / 800 rub. Discount: 700 rub.	2
DC1316-8201630012	Guide (tool) for centering the clutch and release (H4M-JR5/JH3) original 8201630012	Original	2000 / 1800 rub. Discount: 1600 rub.	1
DC1963-21102301035	Left drive oil seal Vesta, Largus, X-Ray article 21102301035 (red 35x57x9)	Original	200 / 120 rub. Discount: 90 rub.	1
DC1818-7701209239	Boot of outer CV joint Duster, Terrano, Captur 1.6 / 1.5 4×4 manual transmission 7701209239 original	Original	3200 / 2500 rub. Discount: 1900 rub.	1
DC1956-21820160121100	Clutch fork boot Grant, Vesta, X-Ray 21820160121100	Original	150 / 100 rub. Discount: 70 rub.	1
DC1964-21102301034	Right drive oil seal Vesta, Largus, X-Ray article 21102301034 (black 35x57x9)	Original	200 / 120 rub. Discount: 80 rub.	1
DC2046-8200544206	Gearbox input shaft oil seal TL4/TL8/JR5 8200544206	Original	1000 / 700 rub. Discount: 500 rub.	1
DC2159-6001548446	Clutch master cylinder Duster and others original 6001548446	Original	4600 / 4200 rub. Discount: 3900 rub.	1
DC2163	Clutch basket Vesta, X-Ray 1.8 21179 JR5 original 21179-1601085-10	Original	7300 / 6500 rub. Discount: 6100 rub.	1
DC2164	Clutch disc Vesta, X-Ray 1.8 21179 JR5 original 21179-1601130-11	Original	6400 / 5300 rub. Discount: 4900 rub.	1
DC2245-7703065290	O-ring, oil pump oil seal, automatic transmission original 7703065290	Original	800 / 600 rub. Discount: 400 rub.	0