Removal and installation of the intermediate shaft ZMZ-406 GAZ-2705
The intermediate shaft drives the oil pump. In addition, camshafts are driven through it
The intermediate shaft rotates in two sleeve bearings.
Removing the intermediate shaft
Remove the upper and lower camshaft drive chains Replacing the chains of the ZMZ-406 GAZ-2705 engine
The lower chain does not need to be removed from the crankshaft gear.
Remove screws 1 and remove intermediate shaft flange 2
Remove the four bolts securing the cover 1 and remove the cover with the gasket.
Pull up oil pump drive 2 with driven gear.
In order to unscrew the nut 3 and remove the drive gear 4 of the oil pump drive, it is necessary to block the intermediate shaft from turning.
To do this, screw two bolts 1 into the threaded holes of the intermediate shaft 2.
Holding the shaft by the bolts 1 with a screwdriver 3, unscrew the pinion nut with a wrench 4.
Holding the drive gear 1 with your hand, remove the intermediate shaft 2.
If it is necessary to replace the bushings of the intermediate shaft, you must first press out the pipe 3 of the intermediate shaft using a special tool.
Then, use the special tool to press out the intermediate shaft bushing.
Inspection, troubleshooting and repair
After removing, rinse all parts in gasoline. Check intermediate shaft. If it has cracks, replace the shaft.
If there are marks, scratches, scuffs, etc. on the shaft journals, grind the shaft journals to the repair size. If grinding to the repair size fails to completely remove scratches, scuffs, etc., replace the shaft.
Measure the intermediate shaft journals.
If the anterior neck diameter is less than 48.95mm and the posterior neck is less than 21.95mm, they need to be sanded to repair size.
The intermediate shaft bushings are not repairable. If they have scuffs, nicks, scratches, etc., they must be replaced.
Greater bushings are available for spare parts.
After pressing the new bushings into the cylinder block, they must be bored to the nominal or overhaul size.
Bore the bushings in one pass to keep the holes aligned.
When pressing in the bushings, set them so that the holes in the bushings line up with the oil channels in the cylinder block.
The sizes of the intermediate shaft journals and bushings are shown in the table.
Nominal and maximum allowable dimensions and fit of the mating parts of the intermediate shaft of the engine mod. 406
Install the shaft in the reverse order of removal. Lubricate the shaft journals and gears with engine oil before installation.