Possible malfunctions of the gearbox and how to eliminate them
- Cause of malfunction
Remedy
Difficult shifting
- Incomplete clutch disengagement, presence of air in the clutch release hydraulic actuator or lack of fluid in the clutch master cylinder
Upgrade the fluid level in the master cylinder reservoir and bleed the clutch hydraulic system
- Loosening of the locking bolts of the heads or forks of the shift mechanism
Tighten the locking bolts
- Burrs on the inner surface of the gear clutch teeth
Deburr
- Broken holes for pins in shift lever housing
Replace shift lever housing or repair by boring holes and pressing stepped pins
Mismatched gear shifting (shifting):
- Thread wear of the conical surface of the synchronizer blocking ring
Remove the gearbox from the car. Remove the front crankcase and check the gap between the blocking ring and the spur ring with a feeler gauge.
If the gap is less than 0.3 mm, then install a new blocking ring, lapping it against the surface of the corresponding gear until a contact surface of at least 80% is obtained
- Deformation of the blocking ring (the ring does not stop on the cone when pressed and turned by hand)
Install a new blocking ring, lapping it against the surface of the corresponding gear until a contact surface of at least 80% is obtained.
Lapping paste KT TU-06283-76
Spontaneous disengagement of gears:
- Loosening the nuts securing the gearbox to the clutch housing or the bolts securing the gearbox housings
Tighten nuts or bolts
- Wear of the ends of the teeth of the gear couplings or wear of the teeth of the spline crown on the gears of the 1st, 2nd, 3rd, 5th gears, reverse and on the input shaft
Replace worn parts
- Loosening the springs of the clamps
Install springs with a load of (60+15) N (6+1.5) kg s with compression up to 10 mm
Noise in gearbox:
- Bearing wear
Replace bearings
- Breakage of gear teeth
Replace damaged gears
- Wear of the working surface of the gear teeth
Replace damaged gears
- Reduced oil level in the crankcase
Add oil to the correct level
- The alignment of the crankshaft and the clutch housing
Check and realign alignment
Oil leak from gearbox:
- Wear of oil seals
Replace oil seals
- Breather contamination or damage
Clean the breather from dirt or replace it with a new one
- Leakage of plugs and crankcase plugs
Restore cork seals
- Leakage of plugs and plugs of the gearshift lock
Restore the tightness of plugs and plugs
- Loose fastening of the parts of the front cover, front and rear crankcases and gear lever housing
Tighten bolts and nuts
- Damaged gaskets or nicks on mating surfaces
Replace gaskets, clean nicks and lap mating surfaces
- Wear of the steel-babbit bushing of the rear crankcase
Replace the rear crankcase or press it into it and bore it to a diameter of 3 + 0.015 mm coaxially with the hole for the ball bearing within no more than 0.05 mm steel-babbit bushing
When all gears are engaged, torque is not transmitted to the cardan shaft:
- Loose fit of the gears on the intermediate shaft
Replace the layshaft or weld the pinion to the layshaft
When you turn on the 2nd, 3rd or 5th gear, no torque is transmitted to the cardan shaft:
- Loose fit of the 2nd, 3rd or 5th gear on the countershaft
Replace the layshaft assembly or weld the 2nd, 3rd or 5th gear to the layshaft