Gearbox Kamaz - maintenance

Maintenance of gearboxes includes periodic checks of their tightness; tightening the fastening of the supporting support to the ten-speed box and the car frame,

levers to the rods of the remote drive and the flange on the output shaft; checking and adjusting the distance between the stop and the stem of the gear divider control valve, which should be 20 ... 21 mm with a free clutch pedal; checking the condition and operation of the divider control cable (the cable should move easily in the sheath).

The cable must be periodically lubricated by disconnecting it from the derailleur and pouring transmission oil into the cable sheath using an oiler.

In accordance with the chemotological map, it is required to lubricate the supports of the front and intermediate rods of the remote control drive through grease fittings, maintain the required oil level in the crankcase and change the oil in the gearbox crankcase once a year.

To check the oil level, unscrew the plug with the pointer. When checking, the pointer should be inserted into the hole until the end of the plug stops in the crankcase.

The oil from the crankcase of a ten-speed gearbox must be drained through three holes, two of which are located at the bottom of the crankcase of the main gearbox, and the third - at the bottom of the divider crankcase.

From the crankcase of a five-speed box, draining is carried out through two holes.

When changing the oil, flush the crankcases of the boxes with engine oil in the amount of 8.5 liters for a five-speed gearbox and 12 liters for a ten-speed one, clean the magnetic plugs from metal particles and fill the oil up to the top mark on the indicator. The oil level is measured 3...5 minutes after filling it.

When the car is moving, the gearbox should work without noise and vibration, the gears should be easy to switch and securely fixed.

Strong uniform or pulsating noise may indicate a large wear of the gear teeth and shaft bearings, loosening of the fastening of the shaft bearing caps, insufficient level or poor quality of the oil in the crankcase.

Difficulty engaging all gears, as a rule, is the result of incomplete disengagement of the clutch. To eliminate the malfunction, it is necessary to adjust the clutch and its drive.

The inclusion of second, third, fourth and fifth gears with bumps and grinding occurs when the cone rings, blocking chamfers of the fingers and the carriages of the corresponding synchronizers are heavily worn.

To eliminate the malfunction, wear parts must be replaced.

Bumps and rattles observed when the gear divider is turned on can be caused by a malfunction of its synchronizer, as well as an increase in pressure in the pneumatic control system of the divider due to contamination of the air channels of the vent cap in the gear shift valve of the divider.

The pressure reducing valve must provide an outlet pressure of 395...445 kPa.

If it is determined that there is no air release in the divider shift valve, then it is necessary to remove and disassemble the valve, wash all its parts including the ventilation cap.

The gears in the gearbox do not turn on due to wear of parts and misadjustment of the mechanical remote drive, destruction of the output shaft bearings or broken; adjusting the position of the stop, the valve for engaging the gears of the divider.

Gears can spontaneously turn off when the car is moving due to wear of some parts, malfunctions and violations of the remote drive adjustments, as well as due to malfunction of the locks of the shifting mechanisms, loosening of blocks and levers.

Oil leakage from the gearbox housing occurs due to wear and loss of elasticity of the output shaft seals, which must be replaced in these cases, and with increased pressure in the crankcase due to clogging of the breather.

If leakage is observed along the sealing surfaces, then it is necessary to tighten the fasteners and replace the gaskets.