Gear shift diagram on KamAZ: gearbox with divider, transfer case, order, mechanism, repair,

Design and principle of operation

Let's consider the location and design of the KamAZ vehicle gearbox. KamAZ trucks are equipped with manual transmissions. They have 5 speeds. The gearbox is switched by pressing the clutch pedals and moving the gearshift lever to the desired position. Since the car is heavy, it is necessary to transfer the gearbox from one gear to another in several stages.

The principle of operation of the KamAZ gearbox is as follows: with a diesel engine it works either in high mode B or in low mode H. They were created to reduce the load on the engine of a heavy vehicle when it is full, and at the same time not force it to work too actively without load.

The design of a KamAZ gearbox with a divider is simple, but it differs depending on the model of the gearbox. Let's look at the KamAZ gearbox diagram, which is found on diesel vehicles. When driving on a flat road, you need to change gears without a clutch. The design of the KamAZ transfer case can be represented by the following formula: 1B - 2B - 3B - 4H - 4B - 5H - 5B.

Switching speeds is carried out as follows:

First, switch the gearbox operating mode from high to low using a lever.
Then release the clutch.
The lever is set to the desired gear, without jumping over them, but turning everything on in order.

There are gearboxes with automatic mode switching.

How does the divider work on KamAZ?

The gearbox divider or multiplier is an additionally installed overdrive, which converts a 5-speed gearbox into a 10-speed gearbox.

The principle of its operation is as follows. The multiplier reduces the ranges between the main gears, tightening the number of gear ratios of the box and expanding them by 20-25 percent.

This modification allows you to improve such vehicle characteristics as:

fuel efficiency;
acceleration speed;
traction force;
controllability.

The mechanism is located in front of the gearbox, or slightly to the right of it, since the main unit does not experience heavy loads and does not require structural modifications. This allows you to repair and adjust the divider yourself if a malfunction occurs.

Location and order of gear shifting on KamAZ

Most cars from the Kama plant are equipped with manual gearboxes with 5 steps (with or without a divider). Gear shifting is carried out by moving the gearbox rocker with the clutch pedal pressed. But gears on trucks should not be engaged directly, but in stages. Theoretically, this reduces the load on the engine when driving with a full load, and when working with an empty body, it saves fuel.

The usual operating modes of the KamAZ gearbox are increased “B” or decreased “H”. In cars equipped with a gearbox with a multiplier, switching from mode “B” to mode “H” is carried out by lowering a special single divider lever.

It is important to know how to engage a higher gear when driving a KamAZ with a full load: experienced drivers recommend engaging the first 4 gears in the heavy secondary “H” mode, and then transferring the 4th speed to the “B” mode, switching to the 5th lower gear, and then go to “B”. The shift order may vary depending on the specific gearbox model.

Transmission conversion for MAZ, Kamaz and Ural

Specialists carry out work on dismantling gearboxes with subsequent installation and configuration of imported gearboxes on Russian trucks of the MAZ, KamaZ and Ural brands.

According to statistics, domestic gearboxes installed on heavy-duty vehicles have insufficient power and often fail. Owners of these cars often contact service centers regarding replacement or re-equipment of the gearbox unit. Our specialists carry out work on installation and optimization of gearboxes in accordance with the technical characteristics and operating conditions of your vehicle.

Our company installs gearboxes from the German company ZF, European Eaton gearboxes, Chinese Fast Gear, as well as other manufacturers. American Eaton Fuller gearbox models are also offered: FRO, FR, Fuller Cina. Brazilian gearboxes are represented by the devices ZF 8S-1350, ZF 16S109, ZF16S151, ZF 16S-1650, ZF 16S181, ZF 16S221. Among the budget options, we are pleased to offer you synchronized and non-synchronized Chinese gearbox models 9JS135A, 9JS135T-A, 9JS135T-B and 12JS200T-A.

For those customers who need to improve the ease of use of the car, we offer a service for synchronizing the Fast Gear gearbox for 9 and 12-speed gearbox models. Synchronized operation of the gearbox will increase the service life of the box assembly. At the same time, we take into account the wishes of customers and offer services for converting the gearbox to non-synchronized operation mode. This applies to gearbox models 12JS160TA and 12JS200TA.

Our specialists also carry out adaptation of all newly installed and optimized gearboxes; technical maintenance in our company is carried out quickly and efficiently. In addition to work related to the removal and installation of the gearbox on your car, it offers services for the installation of hydraulic equipment, as well as a service for diagnosing the clutch assembly. In particular, the operation of the clutch disc and basket, release bearing and flywheel is checked. The operation of the range multiplier on the gearbox and the shifting progress of the SPLITER halves will be checked. Also, as part of the maintenance, specialists will test the display of gearbox readings on the instrument panel, check the shift progress of all auxiliary gears and the inclusion of reversing lights when reverse mode is activated.

For all questions regarding gearbox repair, Sales and Exchange of gearboxes, Installation of hydraulic equipment, Sales of spare parts, please contact:+7 (916) 503-15-96; +7 (915) 354-50-16.

Specifications

The KamAZ gearbox with a divider includes the following elements:

a crankcase in which the drive, driven and intermediate shafts assembled with gears are mounted;
bearings;
synchronizers,
reverse gear block,
top cover of the box,
gear shift mechanism.

The gearbox of KamAZ vehicles can be five- or ten-speed. The gearbox divider has high and low gears and, in combination with the main gearbox, allows for 10 forward gears and 2 reverse gears. The divider system improves the traction qualities of the machine, makes it easier to control, and reduces the frequency of shifting gears with a lever. Transmission ratios are available in the operating instructions for the device.

The 141 KamAZ gearbox has a reversing light switch. To prevent the simultaneous activation of 2 gears, there is a ball-type lock in the cover, and a spring-finger fuse is used to prevent accidental engagement of reverse gear. The gearbox with divider weighs 320 kg. The cuffs are located in the shaft covers. They protect the gearbox from clogging and prevent oil leakage. Insufficient oil volume in the gearbox leads to its damage. When you first fill the gearbox there should be 9 liters of oil, when changing the fluid - 8 liters.

Technical characteristics of the KamAZ-141 gearbox: Carter:

The diameter of the bearing bore is 150 mm.
The diameter of the hole in the gear block axis is 32 mm.

Main shaft:

The diameter of the front bearing journal is 24 mm.
Rear bearing - 59 mm.

The secondary shaft has the following diameters for the parts:

Fourth gear gear bushings - 63 mm.
Roller bearings - 80 mm.
Reverse gear bushings - 70 mm.
The outer diameter of the sleeve is 72 mm.

Intermediate shaft:

The diameter of the front bearing journal is 65 mm, the rear one is 49 mm.
The diameter of the rear bearing cup is 119 mm.
The diameter of the intermediate shaft is 65 mm.
The inner diameter of the gear is 65 mm.

The weight of the gearbox with divider is 320 kg.

TRUCKS GAZ, ZIL, KAMAZ, URAL, MAZ, KRAZ

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Kamaz 141 gearbox design

Fig.1. Gearbox KamAZ 141 (longitudinal section) 1 — clutch release fork; 2 - fork shaft; 3 - input shaft; 4 — clutch release; 5 - hose; 6 — cover of the rear bearing of the input shaft; 7, 14, 17, 26, 28 — bolts; 8, 12, 15, 16, 29, 31, 36 — gaskets; 9 — gear shift lever; 10 — gear shift lever support; 11 — adjusting bolt; 13 — top cover; 18 — rear ball bearing; 19 — worm wheel of the speedometer sensor drive; 20 — driveshaft mounting flange; 21 — flange mounting nut; 22 — cover of the rear bearing of the secondary shaft; 23 — speedometer sensor drive gear; 24 — bearing cover; 25 — washer; 27 - spherical roller bearing; 30 — bearing cup; 32 — drain plug; 33 - intermediate shaft; 34 - gearbox housing; 35 - secondary shaft; 37 — cover of the front bearing of the intermediate shaft; 38 - clutch housing Two cuffs are inserted into the inner cavity of cover 6. The working edges of the cuffs have a right-hand notch. The internal cavity of large diameter is designed to accommodate an oil injection device; spiral blades at the end of this cavity prevent the oil from spinning in the injection cavity by the oil injection ring, thereby reducing centrifugal forces, and therefore contribute to an increase in excess oil pressure in the injection cavity. In the upper part of the gearbox cover 141 Kamaz-4308, 43253 there is a hole for supplying oil from the gearbox oil accumulator to the discharge cavity. The secondary shaft rear bearing cover 22 is attached to the rear end of the gearbox housing and is centered on the outer race of the secondary shaft rear bearing 18. In the rear part of the cover of the gearbox-141 Kamaz-4308, 43253 there is a cuff with a dust collector, on the working edge of which there is a left notch. The speedometer sensor drive gears are installed in the rear bearing cover of the secondary shaft. The cover cavity must be filled with lubricant. The driveshaft mounting flange can be made in two versions - round or with end splines. In the gear shift lever support it is possible to install a VK-403 type sensor for switching on the neutral gear in the box. In the bosses of the right wall of the Kamaz-141 gearbox there is a boring into which the axis of the reverse gear block is pressed.

The axle is protected from falling out by a lock washer screwed with a bolt that has a hole into which a plastic pin is inserted. The pin seals the threaded connection against leakage of lubricant. In the lower part of the crankcase of the KPP-141 Kamaz, drain plugs 6 and 32 (Fig. 1) are screwed into bosses; There is a magnet built into the plug that catches metal particles in the oil. In the internal cavity of the crankcase, in the front part of the left wall adjacent to the front end of the crankcase, an oil accumulator is cast, into which, when the gears rotate, oil is thrown, which then, through a hole in the front wall of the crankcase, enters the cavity of the drive shaft cover and onto the oil injection ring. The gear wheels of the Kamaz 141 gearbox are assembled in pairs with mating gear wheels along the contact patch. The input shaft of the Kamaz-141 gearbox is made as one piece with a gear wheel; its front support is a ball bearing located in the crankshaft bore. The bearing cavity is filled with lubricant and sealed with a cuff. A ball bearing and an oil injection ring are installed on the rear end of the shaft of the KPP-141 Kamaz-4308, 43253 with a stop at the end of the gear, which is prevented from turning on the shaft by a ball. The package is tightened with a ring nut, the collar of which is pressed into the grooves of the shaft. The centering diameter of the shaft, made for the clutch release clutch 142) is 54.9 mm, for the KamAZ MFZ 430 clutch clutch - 60 mm. The free play of the input shaft is regulated by a set of steel spacers 8 (Fig. 1) with a thickness of 0.2 mm and 0.3 mm, installed between the ends of the input shaft and the outer race of the bearing. The intermediate shaft of the 141 Kamaz gearbox is made as one piece with the rims of the gear wheels of the first, second and reverse gears. At the front end of the shaft, the gear wheels of the third and fourth gears and the gear wheel of the intermediate shaft drive are pressed in and secured against rotation by segment keys. The secondary shaft of the Kamaz 141 gearbox, complete with gears and synchronizers, is installed coaxially with the input shaft. At the front end of the shaft there is a bearing with an attached inner ring. All shaft gears are mounted on roller bearings, of which the fourth gear gear bearing is loose, without a cage. The gear wheels of the fourth and third gears of the 141 Kamaz-4308, 43253 gearbox are secured in the axial direction by a thrust washer with internal splines, which is installed in the shaft recess so that its splines are located opposite the shaft splines, and is locked against rotation by a spring-loaded locking key. Along the axis of the gearbox shaft 141 Kamaz-4308, 43253, a channel is drilled for supplying lubricant through radial holes to the gear bearings. Oil is supplied to the channel by an oil injection device located on the input shaft.

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GAZ-3307 clutch maintenance
Steering system GAZ-3307
Gearbox parts for GAZ-3307
Maintenance of the rear axle GAZ-3307
Maintenance of the fuel system of the D-245 diesel engine
Clutch GAZ-3309 with a diesel engine
Operations for disassembling the GAZ-3309 gearbox
GAZ-3309 front axle service
Repair of cardan shafts of GAZ-3309 cars

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Operations for assembling basic components of the ZIL-130 engine
Service and repair operations for the ZIL-130 gearbox
Maintenance and repair of ZIL-130 clutch
Repair and adjustment of the rear axle ZIL-130

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KAMAZ-4310, 43118, 43114
KAMAZ-5320, 55111, 53212, 5511, 55102
KAMAZ-65115, 6520, 65117
KAMAZ-4308
Engine KAMAZ-740

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Parts of the cylinder block and head of the YaMZ-236 engine
Service maintenance of the YaMZ-236 piston group and crankshaft
Diagnostics and technical adjustments of the YaMZ-236 engine
Design and adjustment of fuel injection pump and injectors of the YaMZ-236 engine
Cylinder block and piston YaMZ-238
Components of the YaMZ-238 diesel fuel supply system
Design and adjustment of the fuel injection pump of the YaMZ-238 diesel engine
Technical design of the YaMZ-239 gearbox

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Components of the front axle and steering rods of the Maz-5516, 5440
Steering system of Maz-5516, 5440 cars
Clutch and gearbox parts Maz-5516, 5440
Maintenance of drive axles of MAZ-5516, 5440 vehicles
Power steering for Maz-5551, 5335 cars
Maintenance of cardan transmission of Maz-5551, 5335 cars
Maintenance and adjustment of clutch MAZ-5551, 5335
Repair and service of the rear axle of MAZ-5551, 5335 cars

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Gearbox Ural-4320
Construction and adjustment of Ural-4320 bridges
Maintenance of transfer case Ural-4320
Steering components Ural-4320

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Servicing the KRAZ-255, 260 gearbox
Steering mechanism and power steering Kraz-255, 260
Adjustments and repairs of the power steering cylinder and steering rods of the Kraz car
Drive axle components and drive shafts Kraz-255, 260

How to change gears on KamAZ

To change gears correctly, you need to know how the transmission works. The gearbox is designed in such a way that movement is often carried out at a reduced speed, so the machine can transport heavy loads. KamAZ has a 5-speed gearbox. You need to change gears using the clutch pedal and lever.

Start of movement

Before you start moving, you must press the reduced speed. Shift gears only with the clutch pedal depressed. The gear shift pattern is based on staged gear shifting. To start driving a truck, you need to spin the crankshaft of the internal combustion engine.

The second gear must be engaged when the needle on the tachometer reaches mark 3, which means 3000 rpm. This method of gear shifting will make it possible to extend the life of the gearbox and reduce gasoline consumption.

Switching speeds

Let's consider the procedure for switching gears after the car has already started moving. When KamAZ accelerates, the gear shift order is: 4H - 4B - 5H. To engage speed 2, the crankshaft speed must increase to 3000 rpm according to the tachometer readings. The functions of the crankshaft are basic.

Reverse

To engage reverse on a truck, you need to place the switch in the lower left position. Reverse gear cannot be engaged while the vehicle is moving. To engage reverse, you must first completely stop the unit, then perform a maneuver.

Switching rules under different conditions

Gear changes depend on the various conditions in which the vehicle is moving. These rules should be followed so that during the use of the gearbox it does not fail.

Climb

During an ascent, you must switch the gearbox to mode H, as a result of which the transmission will begin to operate at increased voltage.

The following rules must be followed:

When switching from 1st to 2nd gear when ascending a KamAZ truck, you must use the method of depressing the clutch pedal twice.
In order for the crankshaft to work correctly when changing gears, you need to use the fuel pedal; it also needs to be pressed periodically. At the same time, you can overcome any steepest climb.
The shaft speed when lifting must be more than 2000 rpm. Otherwise, the engine may shut down, which may cause an accident while driving on the road.
During the climb, switch to the desired mode, this will facilitate the operation of the engine and all components of the machine.

Descent

Some drivers turn off the engine when descending a mountain to save gas. This should not be allowed at KamAZ.

If you turn off the internal combustion engine during a trip, the electric booster will not perform its functions, which will lead to the steering wheel locking.

KamAZ braking occurs not only as a result of stopping the engine, but also by activating the auxiliary braking system. When a heavy vehicle is going downhill and the driver applies the auxiliary brakes, the clutch should not be depressed and the driver should not shift from one gear to another.

Icy areas

You need to drive a truck on icy areas with maximum speed and range. When braking, you must use the engine stop assist system. If emergency braking is required, the operator must stop the trailer wheels. If you do not take this rule into account, you may end up in a skid.

It is possible to slow down the internal combustion engine only as an exception, as this can lead to its wear. When braking, the wheels should not slip. To avoid this, you need to turn off the reduced speed, which will help reduce the rotation of the crankshaft.

Skid

When skidding, do not disengage the clutch. When the truck skids, you need to turn the steering wheel in the direction of the skid. If the KamAZ skids, you need to take your foot off the gas pedal and press the differential. This must be done using the regulator located on the panel. As a result, the indicator on the panel will turn on. You need to start the move from the second high gear. After overcoming the skid, the differential should be unlocked.

Switching features in different models

On KamAZ vehicles of various models and configurations (tractor tractors - 44108 or 5490; dump trucks - 6520 or 55111; trucks - 5320, or military model 5350; road trains - 5410, 65206) the following gearboxes are installed:

141, 142 and 144 – mechanical gearboxes, 5-speed (used in light trucks, and are similar in design and operating principle to passenger car gearboxes);
152 and 154 – mechanical gearboxes with a multiplier, ten-speed;
German-made ZF-6S1000 gearbox with mechanical shifting, 6-speed with a full set of synchronizers;
ZF-9S109 and ZF-9S1310 – mechanical 9-speed gearboxes with a range shifter.

Models of gearboxes for trucks differ from each other in the number of stages, the complexity of the device, the design of the rocker and the order of gear shifting. We will give a more detailed description of various gearboxes using the example of several KamAZ models.

Operating manual in PDF »

Design and switching diagram of the KamAZ-5320 gearbox with a divider

The KamAZ-5320 is equipped with two models of gearboxes - a five-speed 142 or a ten-speed 152 with a divider. Switching gears on KAMAZ-152 occurs according to the following scheme:

Specifications:

number of steps – 10;
box control type – mechanical;
divider control type – pneumomechanical preselector;
bearings – roller bearings with and without a cage (gearbox gears), ball and spherical roller bearings (gearbox shafts);
synchronizers – finger-type inertial;
gearbox – front two-stage.

KamAZ-4310: switching diagram

Military trucks of the 4310 model have increased cross-country ability and are equipped with a five-speed three-way gearbox 14 (it differs from the 141 in that it has a direct fifth gear, while the 141 model has a direct fourth gear, the fifth gear here is an accelerating one). The gear shift mechanism is similar to that discussed above for the main gearbox of the KamAZ-5320 vehicle with a divider. The diagram is shown in the photo:

Gearbox KamAZ-43118

KamAZ-43118 is equipped with a KAMAZ-154 model gearbox with a divider, which has a gear shift circuit similar to the 152nd model.

Gearbox ratios:

Gearbox KamAZ-65115

Depending on the modification, the model 65115 dump truck is equipped with a reinforced gearbox with a KAMAZ-154 multiplier, or a German-made nine-speed gearbox – ZF9.

The gearbox with a mechanical control type has gear ratios in the range of 9.48 - 0.75; and 8.97 for reverse gear. Maximum torque – 1300 Nm. The gear shift diagram is shown below:

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Gearbox gearbox KamAZ 141

The Kamaz-141 gearbox is used to transmit torque, change torque in magnitude and direction, long-term disconnection of the engine from the transmission, as well as power take-off to drive auxiliary units. Gearbox 141 is used for Kamaz 43253, 43505, 4308 vehicles. Modernized Kamaz gearbox model 141. During the modernization, the gear couplings of the 4th-5th gear synchronizer, the gearbox input shaft and the 5th gear gear were strengthened by increasing the tooth height, the locks against self-switching off of the 4th gear synchronizer were strengthened. 5th gear, the locking device in the splined connection of the 4th-5th gear synchronizer carriage and the secondary shaft was eliminated, which made it possible to increase the durability of the gearbox by 15-20%. The Kamaz 141 gearbox is used for vehicles with engines with a torque of up to 850 Nm inclusive. The Kamaz 141 gearbox is installed mainly on single vehicles and bus chassis. The Kamaz gearbox type is mechanical, five-speed with a three-way shift mechanism. Kamaz 141 and 142 gearboxes differ in gear ratios. The Kamaz 141 gearbox has an accelerating gear and, with a slight decrease in traction properties, provides the vehicle with a higher travel speed. Technical characteristics of the Kamaz 141 gearbox Gear number and gear ratios: 1 - 5.62; 2 - 2.89; 3 - 1.64; 4 – 1; 5 - 0.742; Reverse gear - 5.3 Gearbox shaft bearings 141 KamAZ -4308, 43253 - Ball bearings are used in the supports of the primary shaft, front roller and rear ball bearings are used for the secondary shaft. The intermediate shaft is supported at the front by roller bearings and at the rear on double-row spherical roller bearings. Gear bearings are double-row roller bearings with cages without rings, fifth gear gear bearing without a cage. Synchronizers - inertial type, pin type with brass cone rings. Gears with helical teeth, except for first gear and reverse gear, constant mesh. The lubrication system of the gearbox 141 is combined, all parts are lubricated by splashing, the gearbox gear bearings also have additional recharge from the oil injection device. Power take-off - from the main gearbox on both sides through hatches in accordance with GOST 12323-66; on the right side - from the ring gear of the reverse gear block; on the left - from the ring gear of the reverse gear of the intermediate shaft; it is possible to install a PTO instead of the top gearbox cover. Kamaz 141 gearbox control is mechanical, with remote drive. Speedometer - the speedometer drive is two-stage, consists of a permanent worm pair and a replaceable pair of cylindrical spur gears. The Kamaz-141 gearbox (modification of Kamaz-142) consists of the following main assembly units: a gearbox housing 34 (Fig. 1), in which the primary 3, secondary 35 and intermediate 33 shafts assembled with gears, synchronizers and bearings are mounted, reverse gear block, top cover 13 of the box with the gear shift mechanism assembly. Clutch housing 38 is attached to the front end of the Kamaz-141 gearbox housing. The shaft bearings are closed with covers with sealing gaskets. The cover 6 of the rear bearing of the input shaft is centered with an internal bore along the outer race of the bearing; The surface of the cover, machined along the outer diameter, is the centering surface for the clutch housing. Fig.1. Gearbox KamAZ 141 (longitudinal section) 1 — clutch release fork; 2 - fork shaft; 3 - input shaft; 4 — clutch release; 5 - hose; 6 — cover of the rear bearing of the input shaft; 7, 14, 17, 26, 28 — bolts; 8, 12, 15, 16, 29, 31, 36 — gaskets; 9 — gear shift lever; 10 — gear shift lever support; 11 — adjusting bolt; 13 — top cover; 18 — rear ball bearing; 19 — worm wheel of the speedometer sensor drive; 20 — driveshaft mounting flange; 21 — flange mounting nut; 22 — cover of the rear bearing of the secondary shaft; 23 — speedometer sensor drive gear; 24 — bearing cover; 25 — washer; 27 - spherical roller bearing; 30 — bearing cup; 32 — drain plug; 33 — intermediate shaft; 34 - gearbox housing; 35 - secondary shaft; 37 — cover of the front bearing of the intermediate shaft; 38 - clutch housing Two cuffs are inserted into the inner cavity of cover 6. The working edges of the cuffs have a right-hand notch. The internal cavity of large diameter is designed to accommodate an oil injection device; spiral blades at the end of this cavity prevent the oil from spinning in the injection cavity by the oil injection ring, thereby reducing centrifugal forces, and therefore contribute to an increase in excess oil pressure in the injection cavity. In the upper part of the gearbox cover 141 Kamaz-4308, 43253 there is a hole for supplying oil from the gearbox oil accumulator to the discharge cavity. The secondary shaft rear bearing cover 22 is attached to the rear end of the gearbox housing and is centered on the outer race of the secondary shaft rear bearing 18. In the rear part of the cover of the gearbox-141 Kamaz-4308, 43253 there is a cuff with a dust collector, on the working edge of which there is a left notch. The speedometer sensor drive gears are installed in the rear bearing cover of the secondary shaft. The cover cavity must be filled with lubricant. The driveshaft mounting flange can be made in two versions - round or with end splines. In the gear shift lever support it is possible to install a VK-403 type sensor for switching on the neutral gear in the box. In the bosses of the right wall of the Kamaz-141 gearbox there is a boring into which the axis of the reverse gear block is pressed. The axle is protected from falling out by a lock washer screwed with a bolt that has a hole into which a plastic pin is inserted. The pin seals the threaded connection against leakage of lubricant. In the lower part of the crankcase of the KPP-141 Kamaz, drain plugs 6 and 32 (Fig. 1) are screwed into bosses; There is a magnet built into the plug that catches metal particles in the oil. In the internal cavity of the crankcase, in the front part of the left wall adjacent to the front end of the crankcase, an oil accumulator is cast, into which, when the gears rotate, oil is thrown, which then, through a hole in the front wall of the crankcase, enters the cavity of the drive shaft cover and onto the oil injection ring. The gear wheels of the Kamaz 141 gearbox are assembled in pairs with mating gear wheels along the contact patch. The input shaft of the Kamaz-141 gearbox is made as one piece with a gear wheel; its front support is a ball bearing located in the crankshaft bore. The bearing cavity is filled with lubricant and sealed with a cuff. A ball bearing and an oil injection ring are installed on the rear end of the shaft of the KPP-141 Kamaz-4308, 43253 with a stop at the end of the gear, which is prevented from turning on the shaft by a ball. The package is tightened with a ring nut, the collar of which is pressed into the grooves of the shaft. The centering diameter of the shaft, made for the clutch release clutch 142) is 54.9 mm, for the KamAZ MFZ 430 clutch clutch - 60 mm. The free play of the input shaft is regulated by a set of steel spacers 8 (Fig. 1) with a thickness of 0.2 mm and 0.3 mm, installed between the ends of the input shaft and the outer race of the bearing. The intermediate shaft of the 141 Kamaz gearbox is made as one piece with the rims of the gear wheels of the first, second and reverse gears. At the front end of the shaft, the gear wheels of the third and fourth gears and the gear wheel of the intermediate shaft drive are pressed in and secured against rotation by segment keys. The secondary shaft of the Kamaz 141 gearbox, complete with gears and synchronizers, is installed coaxially with the input shaft. At the front end of the shaft there is a bearing with an attached inner ring. All shaft gears are mounted on roller bearings, of which the fourth gear gear bearing is loose, without a cage. The gear wheels of the fourth and third gears of the 141 Kamaz-4308, 43253 gearbox are secured in the axial direction by a thrust washer with internal splines, which is installed in the shaft recess so that its splines are located opposite the shaft splines, and is locked against rotation by a spring-loaded locking key. Along the axis of the gearbox shaft 141 Kamaz-4308, 43253, a channel is drilled for supplying lubricant through radial holes to the gear bearings. Oil is supplied to the channel by an oil injection device located on the input shaft.

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Clutch KamAZ-5320 and its components
Repair of PGU and Kamaz clutch master cylinder
Gearbox gearbox KamAZ 141
Gearbox gearbox KamAZ ZF 16
Gearbox 152 Kamaz with divider
Gearbox gearbox 154 Kamaz
Gearbox Kamaz-4308
Clutch of a Kamaz-4308 car
Clutch and gearbox KamAZ-65115
Disassembly and assembly of Kamaz-4310, 55111, 43118 gearboxes

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Cylinder block, head and valves Kamaz-740
Fuel system of Kamaz-740 diesel engine
Adjustments and repairs of fuel injection pump Kamaz-740

Drive axles of the Kamaz-4310 vehicle
Repair of Kamaz drive axle gearbox
Rear axle KamAZ-4308
Axles and suspensions of Kamaz-65115 dump trucks
Installation of Kamaz cardan shafts and axles
Repair of Kamaz vehicle transfer case

Kamaz power steering - adjustments and repairs
Repair of Kamaz steering gear parts
Steering parts Kamaz-4308
Parts of the brake system Kamaz-4308
Brake system and brake drive Kamaz
Repair of brake valves and Kamaz compressor

Suspension Kamaz-4310, 55111, 43118 and their parts
Frame and suspension of the Kamaz-4308 car
Cabin details and platform KamAZ-65115
Cabin components Kamaz-4308
Platform mechanism of Kamaz vehicles

Klintsy KS 65719-5K truck crane based on KamAZ-6522 chassis
Truck crane KC-35719-7-02 based on Kamaz-43118 chassis
Truck crane Galichanin KC-55713-1K based on KamAZ-65115 6x4
Ivanovets KS-45717K-1/1R truck crane based on KamAZ-65115 chassis
Ivanovets KS-3577-3/4 truck crane on KamAZ-43253 4x2 chassis

Malfunctions and repairs

Transmission repair consists of disassembling the unit, diagnosing, repairing or replacing worn elements. After the mechanism is restored, the unit is reassembled and the system is tested in operation. You can contact a service center, but it is better to repair the transfer case yourself.

How to check the oil level

The oil level in the box is checked as follows. Unscrew the crankcase plug. When checking, you must install the crankcase indicator into the hole until it stops. The oil from the crankcase of a ten-speed manual transmission is drained through 3 holes. Of these, 2 holes are located in the lower part of the gearbox housing, and the third is located in the divider. The five-speed gearbox housing is drained through 2 holes.

Change of oil

To change the oil, you need to wash the gearbox housing with engine oil. Clean the magnetic plugs from metal particles and fill in oil to the top line of the indicator. The oil level is measured after 5 minutes. When the car is moving, the gearbox should operate without hesitation, speeds should be switched freely and locked firmly. Loud noise may indicate worn shaft bearings, insufficient oil level, or poor quality lubricant in the crankcase.

How to remove the box

Removing the gearbox is carried out as follows:

You need to remove the driveshaft. To do this, unscrew the 4 fastening nuts.
The PSU is being removed.
Dismantle the starter mountings.
Disconnect the tube that goes to the reduction gear.
Remove the gear shift lever.
Place a jack between the flywheel and the engine pan, and dismantle the engine through a wooden stand.
Unscrew the rear yoke nuts and remove it.
Dismantle the spacer rod.
Unscrew the exhaust system bracket fastening bolts.
Connect the hoist to the bolts and tighten it.
Unscrew the fastening nuts to the side engine mounts.
Unscrew the bolts that secure the gearbox to the internal combustion engine.
Raise the hoist and move the gearbox away from the engine to the output of the transmission input shaft.
Pull out the gearbox.

How to adjust

Now you need to adjust the gearbox and troubleshoot components and parts. If they fail, replace them with new ones. Spline connections must not have defects or chips. Gear bearings should be replaced after first inspecting the place where they are installed to see if there is any wear or areas pressed through by the rollers.

The shaft bearings are replaced because, as a result of breakage and metal shavings getting into the oil, the rolling areas of the bearings were damaged, which could cause gearbox failure. Inspect the gears, detect damage and wear of gear teeth. The conical synchronizer races must not be deformed or worn. The guide shafts should not be loose. There should be no damage to the splines.

How to assemble correctly

The gearbox is assembled in the reverse order. The intermediate shaft is installed in the gearbox housing. Mount the bearings - front roller and rear spherical. Tighten the support washer. Fix it with a nut and close the rear cover of the spherical bearing mount. Install gaskets. The shaft should rotate easily, there should be no jamming of the part when moving.

Repair diagram for KamAZ-5320 gearbox with divider

To repair the KAMAZ-152 gearbox with a divider, it must be disassembled. Analysis includes the following steps:

To disassemble the box, you will first need to dismantle the air switch and unscrew the fasteners;
remove the gearbox shift shaft and fork;
the next step will be to dismantle the fork and release shaft, as well as the synchronizer;
Next, you need to open the rear bearing cover by unscrewing the screws that first fix it;
dismantle the bearing and shaft;
also, to open access to the gearbox multiplier, you will need to remove the support roller washer, metal cup and driven shaft bearing;
using a rubber (not metal) hammer or a wooden block, you must carefully remove the bearing from the multiplier housing, being careful not to crush the part;
next you need to remove the coupling and oil injection nuts using the appropriate wrenches;
The last stage of disassembling the unit is to dismantle the roller bearing, bushing, and gearbox drive gear.

Next, you should inspect all the parts and replace worn ones, and then assemble the device, following the above instructions in reverse order.