Demultiplier ZIL-4331 AMO ZIL 4421-1721010-02 ZIL

And these gear rings, when operating, are in constant engagement with the wheels mounted on the intermediate disk. The reverse movement unit is mounted on special roller bearings, which are located on an axis in the crankcase. Here they are installed quite securely. The reverse drive cardan also works in conjunction with the idler pulley through additional wheels.

Every motorist who has ever encountered driving a ZIL 130 or 131 car will say with confidence that there are practically no obstacles for this “iron horse”. However, if this is your first time driving such a unit, then you will probably be interested in the ZIL 130 gear shift scheme. Moreover, it is quite original and unusual for the average motorist.

If you ignore the difficulties of the gearbox, in the near future the car will be unsuitable for driving.

Common malfunctions of the ZIL 4331 box and options for eliminating them

Difficulty shifting gears can be caused by the presence of nicks on the end side of the gear teeth, a malfunction of the gear shift mechanism, bent forks, or loose fasteners. All parts that cannot be repaired must be replaced. Also try adjusting the clutch release pedal. Other breakdowns:

• the speed turns off with a grinding noise (it’s time to change the synchronizers);
• while driving, the speed is knocked out (the fork of the gear shift mechanism is worn out, it should be replaced);
• the speed does not turn on (the latches or synchronizer pins are broken, you need to buy new ones);
• During operation of the gearbox, a lot of noise is generated (the gear teeth are damaged or the bearings are destroyed, all parts need to be replaced).

Oil may also leak from the ZIL 4331 gearbox (spare parts for it can be purchased here). It is possible that the cuffs have ceased to be elastic, the pressure in the oil crankcase has increased, and the tightness of the seals has been compromised. Replace the cuffs with new ones, rinse the ventilation pipe thoroughly, replace the gaskets, tighten all fasteners.

3.4.2 Gearbox of ZIL vehicles

3.4.2 Gearbox of ZIL vehicles

ZIL trucks are equipped with three-way gearboxes with five forward and one reverse gears.

The gearbox (Figure 3.15, a) includes a crankcase 24, a cover 4 with a lever 5 and a gear shift mechanism, a drive shaft 1, a driven shaft 14 located on the same axis with the drive shaft, synchronizers 9 and 33, an intermediate shaft 22 and a block 26 reverse gears (Figure 3.15, b), mounted on axle 25. On both sides of the crankcase there are hatches with flanges for attaching power take-off boxes, as well as plugs 27 and 17 (Figure 3.15, a), the first of which serves for filling and monitoring the oil level, and the second for draining it.

Drive shaft 1, made integral with gear 2, is mounted on two ball bearings. The front ball bearing 35 is located in the seat of the crankshaft flange, and the rear one is located in the front wall of the crankcase 24.

a – general view; b – reverse gear; c – gear shift mechanism; g – blocking device

Figure 3.15 – Gearbox of ZIL vehicles

The front end of the driven shaft 14 rests on a roller bearing 34 located in the groove of the drive shaft, and the rear end rests on a ball bearing 15, secured in the crankcase with a cover, inside of which an oil deflector is installed. On the splines of this shaft there is a gear 12 for first gear and reverse gear, which is moved by a fork 11.

The front end of the intermediate shaft 22 rests on a roller bearing 31 located in the front wall of the crankcase 24, and the rear end rests on a ball bearing 15. Gear 16 is made integral with the intermediate shaft, and gears 18, 19 and 20 and gear wheels 21 and 23 are mounted on it is on the dowels.

Gear 2 and gear 23, gear 32 and gear 21 of fourth gear, gear 30 and gear 20 of third gear, gear 10 and gear 18 of second gear are in constant mesh.

Gears 32, gears 30 and 10 rotate freely on the driven shaft. They have protruding conical surfaces (cones) and internal gears for connection with synchronizers 9 and 33.

Synchronizers are used for shock-free engagement of gears in the gearbox. Synchronizer 9 of the inertial type includes second and third gears, synchronizer 33 includes fourth and fifth gears. Both synchronizers are identical in design, differing only in size.

Figure 3.16 – ZIL car gearbox synchronizer and its connection circuits

The synchronizer (Figure 3.16, a) is a movable clutch 8 with ribbed rims 5 and a disk 6, which is acted upon by the fork of the gear shift mechanism. The disk has three holes 7 for locking fingers 2, rigidly connecting bronze cone rings 1, and three holes for fingers 4 clamps, which consist of two half-cylinders and two springs 3.

Let's consider the operation of the synchronizer using the example of engaging fifth gear. In the neutral position (Figure 3.16, b), the synchronizer clutch 8 is located in the middle between gears 9 and 10. When the gear is engaged (Figure 3.16, c), by moving the fingers of the 4 clamps, it presses the cone ring 1 to the cone of the gear 9 of the drive shaft. The clutch connected to the driven shaft and the drive shaft gear have different rotation speeds.

Due to friction between the conical surfaces, the ring (Figure 3.16, a) rotates relative to disk 6 of clutch 8 until the conical chamfers of the holes 7 of disk 6 come into contact with the locking pins 2. In this case, the conical rings 1 and clutch 8 are blocked. When the rotation speeds of gear 9 and driven shaft, the coupling moves further along the semi-cylinders of the clamps, compressing their springs 3 (Figure 3.16, d). In this case, the ring gear 5 of the clutch silently engages with the ring gear of gear 9 of the fifth gear.

The gear shift mechanism is mounted in the gearbox housing cover. The movable gears move along the secondary shaft with forks 6 (Figure 3.17, a), which freely fit into their annular grooves. The forks are fixed to the sliders 2 and move with them. The sliders are moved by the lower end of the gear shift lever 3. The lever is mounted in the middle part on a ball joint in the gearbox housing cover.

To prevent reverse gear from being engaged when moving forward, a fuse 7 is installed in the housing 10 of the shift lever (Figure 3.17, b), which consists of a plunger with a spring. Engaging reverse gear is only possible with significant force applied to the gear shift lever.

The fuse is installed in the intermediate lever 11 for engaging first gear and reverse gear. The presence of an intermediate lever reduces the travel of the gear shift lever. Therefore, the lever stroke for engaging all gears is the same.

a – device; b – reverse gear fuse; c – gear lever shift diagram; 1 – cover; 2 – sliders; 3 – gear shift lever; 4 – clamp spring; 5 – gear lock ball; 6 – forks; 7 – reverse gear fuse; 8 – castle balls; 9 – lock pin; 10 – lever body; 11 – intermediate lever for engaging first gear and reverse; I – V – gears; ZX - reverse

Figure 3.17 – Gear shift mechanism for ZIL vehicles

The gearshift locking mechanism prevents two gears from being engaged at the same time. Its two balls 8 (Figure 3.17, a) are placed in the hole in the cover between the sliders 2 and pin 9. The sliders have recesses that are located opposite the balls when the gear shift lever is in the neutral position.

When moving the middle slider, the other two are locked with balls. If the outermost slider moves, the ball comes out of its recess, moves the adjacent ball, which enters the recess of the middle slider, moves the pin 9, which presses on the second balls and simultaneously locks the middle and other outer sliders.

To fix the engaged gear, a latch consisting of a ball 5 and a spring 4 is used. When the gear is engaged, the ball, under the action of a spring, enters the recess of the slider 2 and prevents its arbitrary movement from vehicle vibration.

The process of removing the ZIL 4331 gearbox

First, place the vehicle on a raised platform or in a viewing hole. Then unscrew the bolts securing the cab floor cover. Remove it, unscrew the flange holding the propeller shaft. Next, disconnect the adjusting rod and the special tension spring. It is also necessary to remove the bracket from the transverse frame and carefully release the driveshaft onto the platform with wheels (this will be more convenient).

Common gearbox breakdowns and their causes

If a lot of noise comes from the mechanism, then the reason lies in the synchronizers, gears, bearings or in an increase in the axial clearance. Low-quality oil or its constant absence in the system also contributes to the appearance of extraneous sounds. Other problems and their causes:

• spontaneous knockout of the gear (gear teeth are broken, clamp springs have lost their elasticity, synchronizer rings are damaged);
• Difficulty switching speeds (drive fork is broken, lever is deformed or splined joints are worn);
• overheating of the unit (there is insufficient amount of transmission oil in the crankcase, the seals are worn out);
• divider failure (valves and air lines are clogged, the control mechanism unit is faulty);
• vibrations and knocking (problems with the main or driveline).

If maintenance is not performed on time or is not done professionally, the wear of parts will only accelerate. It is better to entrust this work to experienced craftsmen who know all the nuances of the ZIL 4331 gearbox, spare parts for which can be purchased from us.

Repair of transfer case ZIL-131

Transfer case ZIL-131 is a reliable and durable unit. However, if signs of improper operation of the gearbox appear - increased noise, grinding noise when switching modes, “knocking out” speeds, lubricant leakage, the gearbox should be removed from the car.

Then, at the repair site, the box is disassembled and examined. Faulty parts and assemblies are replaced with new ones. Then the box is assembled and installed on the truck. After adding fresh lubricant, make a test drive and determine the serviceability of the repaired transfer case.

Changing the oil at the ZIL gearbox

If the required amount of lubricant is not available (or its quality is poor), experts recommend carrying out an oil change procedure. First, the crankcase itself is cleaned of accumulated dust and dirt. Then a special plug is removed from the drain hole. Carefully pour the liquid into a prepared plastic or metal container.

There is a magnetic pad on the plug; it collects all metal particles. They also need to be removed. The plug is then screwed back in and clamped securely. Then industrial oil is poured into the crankcase (through a special hole). Next, start the engine for 5 minutes and turn it off. This allows the oil to circulate through the system and remove all dirt.

Then the process is repeated again. The industrial oil is drained, the plug is clamped again, the upper neck of the crankcase is opened and transmission oil is poured. After starting and running the engine, technicians check the lubricant pressure in the system. If it does not reach the required level, topping up is done. You can buy high quality spare parts for the ZIL 4331 truck in our store.

In the 1970s, a plan was developed to produce a powerful, yet economical cargo transport. It meets all the requirements set by the international automotive community. Due to its convenient location in Moscow and the presence of a proven production scheme based on the 130 model, the order was received by the Likhachev plant.

In 1977, a three-axle truck ZIL-4331 was released. This is one of the most famous and recognizable Soviet-made trucks in the world. The all-wheel drive car with a front-engine layout has a three-wheeled 6*6 configuration. The vehicle was originally created for cross-country ability, transportation of goods and people, towing trailers on roads of any kind and rough terrain.

Gearbox ZIL 4331: description

Most ZIL cars are equipped with a 9-speed manual gearbox. The gearbox is equipped with a planetary range and is synchronized in addition to the 1st gear with “reverse gear”. Some versions use 5–8 speed manual transmissions. The clutch mechanism is single-disk, there are peripheral springs and pneumatic-hydraulic boosters in the drive.

The gearbox requires 5 liters of transmission fluid. When there is a ZIL power take-off gearbox, more fuel is needed, approximately 6.5 liters. It is recommended to fill in approximately 3.3 liters of new fuel; it is advisable to choose TSp-15K all-season oil. Its main feature is the presence of low-temperature qualities.

How to prevent gearbox failures

To avoid serious problems, you should have your vehicle diagnosed every month. When changing gearbox oil, it is recommended to use fuel that matches the vehicle system. When draining the gearbox housing, the magnet located on the plug must be cleaned. Add new fluid to the control hole. The breather on the crankcase hatch needs to be cleaned. If you follow these tips, your machine will last a long time.

The three-axle truck ZIL 4331 is a reliable carrier in various industries. The gear housing functions properly when handled properly. Its scheme is simple to understand. Experienced drivers speak positively about the gearbox; the lever is easy to use and does not jam. The gearbox is able to function reliably even at low temperatures of -20 or more.

Specifications

Technical characteristics of ZIL-4331:

Description of the truck engine: it is equipped with 6 cylinders and 2 valves, the type of fuel used is diesel. Engine model: YaMZ-236.

Weight parameters:

• curb weight - 11700 kg;
• transport weight - 4820 kg.