DIY gearbox repair man tga

MAN truck gearboxes are reliable units designed for a long period of operation in various modes and in a wide variety of climatic and road conditions. Despite the built-in margin of safety, malfunctions also occur in them. In most cases, they are the result of violation of the rules of maintenance and operation. Repair of the Man ZF gearbox - Man gearboxes is our main specialization, so we can always provide expert assistance in the shortest possible time.

Control unit maintenance

Replacement of synchronizers, bearings

Replacing the clutch fork repair kit

Assembling an already disassembled checkpoint

The demultiplier carrier burst

Replacing the brake clutches

Replacing the front divider piston o-rings

Replacing the 3-4 gear synchronizer

Differential housing replacement

Shank seal replacement

We determine the cause of the breakdown with 99% accuracy

with the help of a professional
dealer equipment

in 30% of cases, the cause of the breakdown is not in the gearbox itself, but in the adjacent vehicle systems

The cost of repairing which is often much lower than repairing the checkpoint itself

Gearbox shift drive mechanism

Control electronics for shift or clutch actuator

Choose your version

• The client formulates his problem
• We carry out diagnostics to determine the true cause of the breakdown
• Dismantling the unit or repairing adjacent systems
• Unit washing. Disassembly, defect detection, budgeting
• Selection and purchase of spare parts
• Repair work
• Assembly and installation of the unit on the car, oil filling
• Test drive, output diagnostics

Video (click to play).

You know the reason for the breakdown

• Dismantling the unit or repairing adjacent systems
• Unit washing. Disassembly, defect detection, budgeting
• Selection and purchase of spare parts
• Repair work
• Assembly and installation of the unit on the car, oil filling
• Test drive, output diagnostics

• Dismantling the unit
• Unit washing. Disassembly, defect detection, budgeting
• Selection and purchase of spare parts
• Repair work
• Loading the unit

The reason for the most difficult and unpleasant case, when MAN gears are not engaged, is hidden inside the gearbox. The rods and forks of the shift mechanism are strong enough, but they can be deformed or broken during prolonged "power", with crunching and jerking, method of shifting gears. In this case, the only method of "treatment" is disassembly of the gearbox and replacement of damaged parts.

How do tech services cheat their customers?

First of all, we strive to help the client, and then make money.
Therefore, we openly guarantee repairs from the 1st time.

Examples from our practice, when services unfairly profit from clients

1) In the estimate for the repair, they indicate the details of the production of ZF or Euroricambi, and in fact install the details of the production of CEI (cheaper and much lower quality). The benefit can be several tens of thousands of rubles

Examples from our practice, when services unfairly profit from clients

2) In the estimate for the repair, new parts are indicated, and in fact the used parts are installed. The benefit can be several tens of thousands of rubles

Examples from our practice, when services unfairly profit from clients

3) They can cheat when troubleshooting, i.e. slip worn and defective parts from another box, you pay and you will have new parts in the box, and your serviceable ones will be used according to scheme number 2

Examples from our practice, when services unfairly profit from clients

4) Oil fraud schemes are also frequently implemented. Instead of oil of the proper specification, anyone who is at hand or even used oil can be poured! Doesn't fit in your head right? But it fits in the pocket, usually of an ordinary locksmith staff 2-3 thousand rubles.

Thanks to modern European equipment and a high culture of production, you can not think about the quality of repair with us.

Tool storage area, stainless steel workbenches.

Professionalism and the availability of the necessary means of production allow us to maintain a high rate and productivity of labor during disassembly, troubleshooting and assembly of the unit.

Tool storage area, stainless steel workbenches.

Modern electrical equipment allows us to repair any electronic systems of trucks. We also have dealer diagnostic equipment, so you don't have to worry about the accuracy of the breakdown and the quality of repairs.

Press, Goose crane, Stacker

The service is fully equipped with all the necessary, expensive equipment, allowing to carry out repair work of any complexity at the proper level of quality.

Before starting repair work, we wash all the parts of the unit in a special wash, which removes all old oils and dirt from the mechanisms, which will have a beneficial effect on work in the future and greatly simplify the repair process.

Repair of all units is carried out on a special tilter, which fixes the part in a position convenient for access by any tool. At the same time, not a single detail is lying somewhere on the floor, as in most services.

We will prepare all the necessary documents for you, pick up any part within 15 minutes and check its availability in the warehouse. We will also provide you with all the necessary information on the repair and maintenance of your truck.

Message vorzhev "02 Jul 2017, 17:39

Hello everyone.
In general, ECAM on my car ordered to live a long time. For a long time I had been hatching the idea of ​​converting to a 4-circuit system.
For this, a used dehumidifier with a 4-circuit, two limiters for 8.5 and 10 bar was purchased. + 4 sensors, everything is assembled, a 4-liter regeneration receiver, wires, chips, a plastic corrugation, and of course electrical tape.
I cleaned the dehumidifier, went through the restrictive ones with the replacement of the canister and the adjustment for the fur. monometer.
The wiring braid had to be assembled from scratch.

Well, away we go, in general, see for yourself.

I put it in the frame in order to make room for a second tank or under some kind of pallet, it will be seen further.
Gathering everything in a heap, I went to the diagnostician for the firmware of the ZBR unit.
ATTENTION - I picked up the sensor chip only with the permission of the diagnostician, I was afraid to burn something.
It took about two hours to flash and check the ZBR, and in the end everything worked.
Air pressure began to show from sensors, ECAM dropped out of the list.

For the money, about 45 thousand rubles came out. 4 days of hard work, used spare parts, did everything myself.

Repair and maintenance manual MAN TGA since 2000. The manual contains general information about the device of the car and their modifications, recommendations for operation and maintenance, descriptions of possible malfunctions of the engine, transmission, chassis, steering and brake system. The tips in the manual will help you carry out maintenance and repair both at a service station and on your own. Details (content, specifications, full information) about the book on the official website of the publishing house "Monolit"

Video MAN TGA gearbox repair (first part) channel Publishing house Monolith

We carry out overhaul, diagnostics and restoration of mechanical transmissions ZF, EATON installed on trucks and special equipment MAN F90, F2000, TGA, TGX, TGS, TGL, TGM, NEOPLAN buses

Box repair MAN produced in several stages:

-primary diagnostics and identification of possible causes without removing the gearbox from the car
-remove the gearbox
- removal and inspection of the clutch unit, if necessary, replacement
-disassembly, troubleshooting of faulty parts of the gearbox ZF, EATON
- drawing up a fault finding map
-coordination with the customer of the cost of spare parts to be replaced
-replacement of all necessary spare parts
-assembly and adjustment of the box ZF, EATON
-installation of the check point on the car
- clutch calibration (if required)
-testing of the gearbox on the car

A guarantee is provided for all types of work!

The term of the gearbox repair, if spare parts are available, is 1 day!

By trucks MAN mechanical boxes of series were installed ECOSLIPT ECOMID, ECOLITE, automatic boxes series AS TRONIC, ECOMAT, ECOLIFE and new development TraXon.

The main types of gearboxes installed on MAN vehicles:

ZF 5S42, ZF 9S1310, ZF12AS2330, ZF16S151, ZF16S181, ZF16S221, ZF 16S109 (1304050026), ZF 6S850, ZF 16S1620, ZF 16S1650, ZF 16S1820, ZF 16S1920, ZF16S2220, ZF16S2230, ZF16S2520 (1343002001), ZF16S2523

EATON RTSO 12316 / TSO 11612 / RTO 11613 / FSO 8209 / FSO 5206. Can be installed retarder (Tbrake retarder).

Retarder brake (retarder) - a device designed to reduce the speed of a vehicle without activating the main braking system.

At the installation site, primary retarder brakes are distinguished - installed on the input shaft of the gearbox or on the engine shaft, and secondary ones - on the secondary shaft of the gearbox. If the retarder is combined with a gearbox, it is called integrated: company ZF even introduced a separate name for it - "intarder". It is not connected directly to the output shaft, but through a pair of gears with a gear ratio of approximately 1: 2, so the rotor speed is twice as high here (which improves the braking torque characteristics at low speeds).

• Like
• I do not like