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.

Removal, troubleshooting and repair of the intermediate shaft of the ZMZ-406 engineRemoving troubleshooting and repair of the intermediate shaft of the ZMZ-406 engine

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.

Removal, troubleshooting and repair of the intermediate shaft of the ZMZ-406 engineRemoval troubleshooting and repair of the intermediate shaft of the ZMZ-406 engine

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

Nominal and maximum allowable dimensions and fit of mating parts of the intermediate shaft of the engine mod. 406Nominal 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.