Gearbox ZF 16 DIY repair

Hello everyone, now I decided to create an informational topic - repair of the zf box, in this case installed on a KamAZ 6520. The reason for the removal was the spring found in the crankcase cover of the ZF box. It flew off the disk, but opening the gearbox zf along the way to replace the 5-6 gear synchron. On a cold one from 4 at once to 6 from a slide, of course, and on a hot identity I was picking my brain. After two years of operation, 6 was also influenced by such a switch.

In short, it was decided - repair with a photo session, since upon request, repair of the gearbox zf no information is available.

I’ll say right away that attention is not forgiven, I don’t write a dictation, and there was no fantan at school with the Russian language.

we start the analysis from the back of the flange, removed with an ordinary china and a puller

Yes, I forgot the backstage, remove it, twist 10 bolts

and even if the glass saline is not flowing and you do not need an oil pump, you do not need to turn their bolts

Continue with the left faucet, too, remove the bolt there hiding holds the clutch cover

1. bolt hole
2. broken hairpin after hitting the crane with a sledgehammer

Removing the rear cover of the gearbox zf 16S151

1. puller mounting holes
2. hole for the direction of the oil pipe (when assembling)
3. the fork mounting bolt are on the same axis, unscrew both (after parsing the diaphragm)
4. speedometer sensor
5. mark the body of the diaphragm when removing to unscrew
6. coaxial bolts
7. Dutch speed

1. first we break off the diaphragm nut 3
2. then coaxial bolts 1-2

I will say right away that the cover was removed with the help of the installers and the sledgehammer had to go through the shobs to avoid damaging the parts. They pulled the cover up and tapped on the shaft. If I have to open it again, I'll make a simple puller, well, I'll spend a maximum of an hour, but I'll calmly stretch it out. which I advise you to create a puller first.

1. bolt fastening to the cover 4 pcs
2. puller plate (I think 15mm is enough)
3. good nut
4. the bolt is even better and longer than the thread, and the diameter. well 30mm at least

saw how the fork stands zf

pulled out the tube and remove the plate

We take out the heavy diff

1. diff
2. reverse gear shaft zf
3. rubber ring

take out the ZF shaft of the differ fork

1. puller mounting holes
2. hole for the direction of the oil pipe (when assembling)
3. the fork mounting bolt are on the same axis, unscrew both (after parsing the diaphragm)
4. speedometer sensor
5. mark the body of the diaphragm when removing to unscrew

• first we break off the diaphragm nut 3
• then coaxial bolts 1-2

Continuation of the repair, unscrew:

1. shaft retainer
2. retainer plug
3. spring traverse fastening holes (box fastening)

1. rubber ring
2. bushing under the diff (skirt in front of the gearbox)
3. gear wheel back (convex part back of the gearbox)
4. gear shaft back (with a tube back to the gearbox)

from the bottom a cover for installing a gear wheel

zf diaphragm housing can be undisassembled

we turn the gearbox ZF with the input shaft to the top, unscrew it and knock it down without screwing about bolt 1 near the wings

I just took off the stopper, took a hammer and the iron bar smashed the gear zx, it turned out okay, the current went under the press for a long time, faster and more efficiently.

• removed the cover, unscrew the two stoppers on the divider fork

squeeze the smaller shaft to the right and lock it with a screwdriver or something else

carefully take the primary one together with the synchro and the plug and take out

sprinkle the synchronization, collect it neatly there, everything is just the soldiers and want to fly away, you have to hold each one when installing it in place

now we take out the small shaft zf pay attention to the slot in the end for the drive oil pump which remained in the casing. when assembling, combine

we bring down the gearbox to one side so that the oil tube is from the top in order not to twist it along with the shaft

To pull out the shaft, you need to press the forks shafts lock

1. retainer
2. I pressed the hole with a screwdriver, the latch stroke is about 4-5mm (repeat when reassembling)

removed the stopper and knocked the gear zx ZF

time is evening tomorrow Friday, in short, he took the shaft and weaved to the edge

the gearbox for 8 years was not disassembled, only the glass was probably removed to replace the oil seal.

bearings all (daewoo hungary daewoo hungary) in good condition gears all in excellent condition synchronous 5-6 brake surface wear stood with bronze brakes. replacement entirely.

set with iron brakes, that is, rubbing surfaces. they said that iron is better and the price is less.

serviceman's answer. installed iron 25t rubles for foreign cars with bronzes 48t rubles for KamAZ to replace the synchron gave the shaft to the repair service zf in Krasnoyarsk said 25000+ replacement 1000 still bought 2 saliniks for a glass and a flange. 1 boot (900r) on the wings

4 small 2 large bronze sliders in the shift forks of the pre-gear gasket set zf said 3200 took (3800) in the process of repair called said that there is no BEARING SLEEVE. synchron, that is, the inner race of the bearing + (2200)

the box zf 16S151 did not open exactly, it was visible on the bolts, it is interesting how it left for 8 years.

the amount for all 33,000 rubles was also announced

in short, 37,000 in total, if only I took the box to them - for the repair of ZF boxes (parsing, defecting, assembly) 20,000 +37,000 well, yes, + how many they attributed to install the shaft, a special puller was designed

rope with two straps at the ends

we guide the forks shafts and the retainer is unforgettable

knocked on the iron with a flange so that the bearing came out of the cover for ease of assembly

The ZF box is typical for cargo versions of the car. The concern ZF Friedrichshafen AG is the developer of the automatic transmission (9th century), which is suitable for installation on cars with front-wheel drive. ZF transmission allows you to effectively adjust the ratio of gear ratios.

ZF Gearbox is a transmission system with a long working life. The ZF-Ecosplit gearbox consists of a 4-speed gearbox, a range multiplier and a front splitter. It is found on main-line KAMAZ vehicles, is distinguished by productivity of work, and has a low noise level.

KAMAZ vehicles equipped with a 16-speed gearbox (16S151 ZF) are reliable in operation. The diagram of this device clearly reflects the design features of the system. There is a main gearbox, a front gear divider and a range multiplier. These are the parts that relate to the transmission system. The gearbox housing has special holes, which makes it possible to check the oil level in the ZF box.

For trouble-free operation of the ZF gearbox, the car should be periodically serviced. Repair of the ZF gearbox is relevant if the work of KAMAZ began to deviate from the norm, for example, characteristic knocks and jolts appeared during a speed change.

To avoid premature repair of the ZF box, proper care of this unit helps. In particular, the motorist must independently check the oil level. Its excess or deficiency is the reason why the automotive system fails. By making a choice in favor of synthetic oils, the driver extends the service life of the box and its constituent parts.

It is better to order repair of the ZF checkpoint in the service center. Here, using the defect detection method, it will be precisely determined what kind of malfunction there is on the car. The oil is drained, which must be checked for its external condition, whether it is cloudy or not. It is advisable to measure the axial play of the shafts, after which the repair of the ZF gearbox begins (disassembling the box). At this stage, worn parts are found that need to be replaced. Also, the system is monitored for cracks, chips. It is important to disassemble the gearbox if the box temperature is high.