In detail: do-it-yourself repair of the Maz 202 gearbox from a real master for the site my.housecope.com.
The MAZ gearbox is a gearshift mechanism that is included in the transmission device together with a divider.
The device and scheme of gear shifting MAZ depends on the model of the gearbox. There are 5-speed, 8-speed and 9-speed gearboxes.
The design of a five-speed gearbox in MAZ includes such elements as:
- primary, secondary and intermediate shaft;
- rotating bearing;
- gears;
- crankcase, switch and rear cover;
- fasteners;
- container for oil liquid.
The mechanism that changes gears is located in the passenger compartment of the vehicle. When the lever of the switching device changes its position, the articulated joint engages with a recess, which is located on one of the axes. At this moment, the end of the hinge is in rigid engagement with the fork device. The forks fit into the hole on the drive gear for forward (gears # 1, 2, 3, 4) or in the fifth gear position (reverse). A short circuit begins in the torque circuit, due to which the secondary axis begins its movement.
The device of an eight-speed box (KPP-202) includes:
- crankcase;
- movable gears;
- intermediate type shaft;
- constant mesh gears;
- drive shaft;
- slots;
- toothed crown;
- cover;
- driven shaft;
- reverse gear block;
- axial reverse mechanism.
After the vehicle starts moving, picks up the required speed, you can change gears in the following order: 4H-4B-5H. In order to activate the second speed, you need to wait until the crankshaft speed increases to 2000 rpm. This indicator can be monitored using a tachometer.
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It is not recommended to start shifting gears at a lower number of crankshaft revolutions, otherwise the mechanism will fail.
To engage reverse, set the switch lever to the down position.
The design of a 9-speed box 238 with a demultiplier includes the following parts and mechanisms:
- hitch case;
- pad;
- gearshift fork;
- right shaft;
- reverse gear washer;
- lazy reverse gear;
- intermediate type shaft roller bearing;
- mounting bolts and nuts;
- spring washer;
- sealing ring;
- retaining ring;
- needle bearing;
- clutch fork bushing.
Disengage the clutch before driving. Before starting off, it is necessary to check the position of the lever, it must be lowered. Switching speed modes is carried out in several stages. At the first stage, it is recommended to use the following switching scheme: 1B-2B-3B. During the further movement, you can go to the scheme: 4H-5B-5H.
In order to change the oil in the MAZ gearbox, you must:
- Drive about 5-10 km by transport to warm up the old oil in the box. At elevated temperatures, it becomes liquid and is easy to drain.
- In 10-15 minutes after stopping the engine, place the vehicle on a lift or inspection pit.
- Remove the protective cover for the crankcase.
- Unscrew the plug and check the volume of oil in the manual transmission.
- Check the gasket for wear, replace it with a new one if necessary.
- Replace worn filter elements.
- Open the drain hole and drain the oil into a prepared container.
- Fill with new oil.
- Screw on the drain cap.
- Refit the clutch guard.
- Start the engine, check the oil level at different speed limits.
An oil change is necessary when maintenance is carried out or gears are poorly included.
Dismantling the MAZ gearbox:
- Place the truck on a special platform.
- Dismantle the batteries.
- Remove air filter elements.
- Detach the splash guards located in the engine compartment.
- Remove the front suspension cross member.
- Drain oil from gearbox.
- Disconnect speed sensors, reverse switch.
- Remove the powertrain harness holder.
- Loosen the fixing screws.
- Remove the electric starter from the hitch housing without disconnecting it from the wire.
- Unbolt the front and rear support mechanisms from the gearbox bracket.
- Disconnect the left support and disengage the input shaft.
- Remove transmission.
In order to put the KAMAZ box in place, it is necessary to repeat all the steps in the reverse order.
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To order the auto parts you need, use the order form on our website
or send us a request in a simple form by email,
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Delivery to the transport company is free, the carriage of goods can be paid for in cash or by bank transfer at the rates of transport companies.
In fact, both those who attribute the box to the Yaroslavl people and those who attribute it to Mazovian products are right. The thing is that until 2004 YaMZ did not manufacture 9-speed gearboxes - the prerogative was for the 236/238 family. But the aforementioned 8-mortar tractor simply "killed", and for it, as well as a couple of MZKT tractors, they made the KPP-202, developed at YaMZ, and produced by the MAZ profile division.
In various versions, this box is used on cars with engines YaMZ-238B, YaMZ-238D and YaMZ-7511 with clutches of 161 and 184 models, respectively. And now about the box itself.
As already mentioned - 9-speed, but these nine gears are obtained due to the combination of nodes:
- classic 5-speed gearbox;
The gearbox control is mechanical, the range control is pneumatic. Synchronizers are present in all gears except ... right, first and reverse. By the way, it is the design of the synchronizers, as well as the dimensions of the gears of the modification of this gearbox that differ from each other.
Of the features of the KPP-202, it is possible to note the presence of an ABS in its device. Confused with the ABS is not worth it, this is a completely different "opera", although it is also about blocking. In this case, we mean the automatic transmission blocking system, its task is to prevent premature transition to the lower range at high speed. That is, neither by mistake, nor by accident will it be possible to turn on the wrong gear now.
Many drivers complain about the "capriciousness" of the checkpoint-202, they say, with a lack of oil and with its low quality, it refuses to work. In fact, this is a real advantage, which does not allow the driver to forget about his duties. And if it so happened that the problems with your box are more serious than a simple whim, then the Internet store "Leader" LLC is at your service. You can buy KPP-202 from us, as well as accessories for it. The quality of the goods is guaranteed, and the prices are pleasing (discounts for deferred payment and other bonuses are possible). If necessary, we will arrange delivery to any region of Russia.
In case of faults in the MAZ gearbox, the crankcase and the cover are subject to repair.
All other mechanisms with significant wear or damage must be replaced.
Urgent repair of the gearbox cast-iron crankcase is carried out if:
- Bores for bearings and pins are worn out;
- The thread is damaged.
To repair the checkpoint at MAZ, bushings are installed.
The hole must be bored to d fifteen and a half centimeters, and the groove is made three millimeters larger in diameter.
- The depth is two point five tenths of a millimeter.
- Bushings must be pressed into the prepared sockets.
- Provide tension not> 0.15 mm.
- The holes are bored linearly.
To repair the MAZ 238 gearbox of damaged threads, glue screwdrivers are used.
If the M16 holes are worn out, drill with a diameter of 17.1 mm. Thread cutting is done. Then the screw is screwed in.
- Reaming is performed to repair the holes.
- When repairing a MAZ gearbox with a crankcase divider, it is necessary to comply with the established requirements of the manufacturer for the interposition of surfaces.
Restoration and repair of the MAZ gearbox of the cast-iron cover is carried out when:
- Cracks;
- Worn out holes;
- Damage to the ends.
If even the smallest breaks are visible on the pipe, it is necessary to cut off the deformed section. Then, the hole d is bored five and a half centimeters for the repair sleeve.
The chamfer is grinded 5x45 degrees. A sleeve is pressed into the prepared hole. The part in the process of repairing the MAZ checkpoint is welded with its own hands. Grinding and boring of holes is performed.
Having placed the lid in the cartridge, the butt is trimmed. The hole is grinded and the chamfer is bored. Then four turns are cut. They observe a step of four, a width of three, and a depth of one millimeter.
The final processing and repair of the MAZ gearbox with their own hands is done on a circular grinding machine.
- The damaged bolt holes are welded with an electrode.
- The fusion is cleaned.
- Drill small holes d eleven millimeters and countersink them from the side of the pipe.
When repairing a MAZ checkpoint, the covers strictly comply with a number of requirements:
- Runout of the holes for the oil seal - no more than 0.08 millimeters;
- The permissible non-parallelism of the ends of the flange and the groove is no more than 0.05 millimeters;
- Runout of the surface of holes with a groove is not> 0.02 mm.
If the hole for the oil seal is worn out, a bushing is used to repair the gearbox at MAZ. First, bore with a diameter of 68 mm and a length of 24.5 mm. Then the bushing is bored. The hole is aligned with the oil groove in the cover. The end of the sleeve is trimmed. Chamfer and hole are bored.
Repair of the MAZ gearbox with a divider is performed on special equipment.
Do not forget that in our online store you will find the highest quality MAZ spare parts for gearbox repair.
The gearbox of the MAZ-5335 and its modifications during repair is disassembled in three stages: partial disassembly, general disassembly of units.
- Unscrew the oil drain plugs, the bolts of the intake cover 20 (Fig. 1) of the oil pump are removed from the gearbox assembly with a magnet, and the intake cover gasket is removed from the intake.
- Unscrew the nuts of the remote gearshift mechanism to the upper roof, remove the spring washers, the mechanism and the gasket of the remote gearshift mechanism from the studs.
- Unscrew the bolts securing the top cover 13 to the gearbox housing 18, remove the top cover assembly with the rod and forks and the cover gasket from the crankcase.
- Unscrew the bolts and remove the covers of the power take-off hatches and their gaskets.
- Unscrew the nut securing the flange 16, after removing the cotter pin, remove the washer and with a puller (Fig. 2) remove the flange 16 (see Fig. 1) securing the propeller shaft to the driven shaft of the gearbox.
Unscrew the bolts of the cover 15 of the rear bearing of the driven shaft, remove the cover with the oil seal and the speedometer drive.
- Remove the spring of the clutch 1 for engaging the clutch, unscrew the nut that secures the hose for lubricating the bearing to the clutch housing 4, unscrew the hose assembly from the clutch and remove the clutch 1 assembled with the bearing from the cover 3 of the rear bearing of the drive shaft.
- Unscrew the clamping bolt of the clutch release fork, remove the spring washer from it and, pushing the clutch release fork shaft with the splined end forward, remove the fork. Then the key is knocked out of the shaft groove and the shaft is removed from the hole in the clutch housing 4.
- Unscrew the bolts securing the cover 3 of the rear bearing of the drive shaft 2, remove the cover 3 assembled with the oil seal and remove the drive shaft 2 assembly from the gearbox housing 18, using a puller.
- Move the driven shaft 14 assembly forward until the rear bearing comes out of the socket, remove the retaining ring from the annular groove with the tongs and press the rear bearing and the worm 35 of the speedometer drive gear from the driven shaft with a puller. After that, they are removed from the gearbox housing 18 into the assembly shaft 14 and removed from the spline surface of its first gear and reverse gears.
- Unscrew the bolts securing the oil pump 25 to the gearbox housing, remove the pump 25 assembly and gaskets.
- Unscrew the bolts of the rear bearing cover of the intermediate shaft 17, remove the cover gasket. Remove the safety wire, two bolts of the thrust washer of the rear bearing of the intermediate shaft 17 and remove the washer. Take out the axle 26 of the reverse gear block and the gear block 27 with bearings. Roller bearings and a spacer sleeve are removed from the reverse gear block 27. The intermediate shaft 17 assembly is advanced until the rear bearing of the intermediate shaft comes out of the gearbox housing 18, the locking ring is removed from the bearing groove with pliers, the bearing is pressed from the shaft and the intermediate shaft 17 assembled with gears is removed from the gearbox housing.
- Remove the cotter wire, unscrew the clutch housing bolts 4, remove the spring washers from the bolts and remove the clutch housing from the gearbox housing 18. Then, the oil level control plug and the oil channel plugs are removed from the gearbox housing.
In this article, we will tell you what functions the gearbox performs in the MAZ engine, we will make several recommendations for repair, and the MAZ gearshift scheme with a divider will also be indicated, which you can examine and study in detail.
In the gearbox there is such an element as a gear, usually there are several of them, they are connected to the gear control lever and it is due to them that gear changes occur. The speed of the vehicle is regulated with the gear change.
That is, in other words, gears are transmissions. They have different sizes and different rotational speeds. In the process of work, one clings to the other. The system of such work is due to the fact that a large gear clings to a smaller one, the rotation increases, and at the same time the speed of the MAZ car. In cases where a small gear clings to a large one, the speed, on the contrary, decreases. The box consists of 4 speeds plus a rear one. The first is considered the lowest and with the addition of each gear the car starts to move faster.
The box is located in the MAZ car between the crankshaft and the cardan. The first comes directly from the engine. The second is directly connected to the wheels and drives them to work. The list of works that lead to speed adjustment:
- The motor sets the motion for the drive and crankshaft.
- The gearbox gears receive a signal and move.
- Using the gear lever, the driver selects the required speed.
- The speed selected by the driver is transmitted to the propeller shaft, which drives the wheels.
- The car continues to move at the selected speed.
The diagram of the gearshift device for a gearbox with a divider on a MAZ is not simple, but it will greatly help you when performing repair work. A stepped gearbox at MAZ consists of such elements as a crankcase, shafts, a mortar, synchronizers, gears and other equally important elements.
Such a unit is installed, in most cases, on trucks or cars that will be exposed to high traffic.
This unit, like its predecessor, is popular among heavy duty vehicles.
The most popular among passenger cars.
Want to keep your divider box in good condition for years to come? Then she needs care and elementary checks. It is necessary to monitor the operation of such elements as gears, a mortar, the control lever itself, and so on. Did it happen that breakage can no longer be avoided? We will give you the following guidelines for self repair:
- familiarize yourself with the diagram and instructions for your mechanism;
- in order to carry out repairs, first of all, it is necessary to remove the box completely and only after that you can start repairing;
- after you pull it out, do not rush to disassemble it completely, sometimes the problem is on the surface, pay special attention to all the details, if you see suspicious "behavior", then most likely the problem is in this element;
- if you still have to disassemble the box completely, put all the parts in order of disassembly, so as not to get confused when you put it back together.
If you are not confident in your abilities, do not have certain skills and knowledge, contact the service center. There is no such possibility? Well, it's never too late to learn new and useful things. Ask questions in the comments, we will give you disclosed and detailed answers.
This article examined the gearshift scheme for all types of MAZ. We hope that the information was useful to you in the repair. Let your box serve you for many years!
You can see the principle of the mechanical box in this video.
How to remove the secondary shaft of the yamz 236 gearbox without removing the box from the engine.
Tips for disassembling the KAMAZ gearbox and its breakdown! # kppkamaz # disassembly # troubleshooting.
It all started with a crack and an oil leak, an autopsy showed that the crack was the result of the ear breaking off.
Checkpoint MAZ, what and how we are doing, everything is clear in the video!
In what condition were the MAZ gearbox units, this must not be allowed!
I'll tell you a bit about the work done.
removed the box to replace the clutch. everything, practically, into the trash.
How to replace the gearbox oil seal, input shaft Link to the group in VK:
12JS200TA Shaft Gear 12 Speed Gearbox Parts Review - Gearbox Parts and Repair. Convenient search for spare parts by.
Instructions for caring for a 2.5 ton AMO-3 truck. 1932
Stage 1 acceptance certificate dated December 19, 2014
Acceptance certificate of stage 2.1 dated June 30, 2015
Delivery-acceptance certificate of stage 2 dated April 29, 2015
Acceptance certificate of stage 3.1 dated December 18, 2015
Stage 3 acceptance certificate dated October 2, 2015
Supplementary agreement No. 3 to the state contract EPM-OKR
Supplementary agreement No. 1 to the state contract EPM-OKR
Additional agreement No. 5 to the state contract EPM-OKR
Listening to the polemics of the drivers of MAZ vehicles and those displeasure with the YaMZ-238 checkpoint, you involuntarily read over the options for installing other checkpoints. I personally had no complaints about the YaMZ-238 checkpoint. Well, not in a hurry to change gears. Yes, not quite easy gear shifting, thoughtfulness in cold weather in shifting the demultiplier. Here, apparently, basically everything, no later, it appeared and I have a complaint - a small gear ratio of the first gear, or it would be better to also make a creeping gear to it. But no matter how it was, on three cars I had a YaMZ-238 checkpoint and thank God it was successful. In addition to the oil seals and the plates of the de-duplicator synchronizer, I did not buy anything for it. Spare parts B./U. of course I did. After talking at some point with the aggregator at these checkpoints and telling him my experience of communicating with the box, I heard such a conclusion from him. You are just very lucky, we suffer with them, bearing breakage on the intermediate shaft and breakdown of the secondary shaft are quite common. As soon as I switched to the 238 checkpoint, I immediately got rid of all 236 boxes.
But now the main thing. If we have a YaMZ-238A checkpoint on the MAZ-54323, then with modern tubeless tires with a size of 315 / 80-22.5 having a statistical rolling radius-0.499 meter speed characteristic will be as follows;
The maximum speed will be as follows 102.158 km / h.
If, for any reason or desire, we install a five-speed gearbox instead of the YaMZ-238A gearbox, then with the same rubber we will get other speeds.
As you can see from the table, the speeds will become such, but it's no wonder, because the gearbox range has decreased significantly.
The maximum speed has become 109,897 km / h. As you can see from the table, the maximum speed has increased, but the starting speed in the first gear has also increased. And also the car, through this gearbox, has become less adapted to changing road conditions.And it will be more difficult for the driver to select the engine speed in the green zone of the tachometer.
But suddenly, by some fortunate coincidence of circumstances, you fell into the hands of a new six-speed gearbox of the Yaroslavl plant and you decided to install it. How the speed characteristic will change. To do this, take and calculate.
As you can see from the tables, the maximum speed will be 96,70 km / h. Looking at the table of speeds of a six-speed gearbox, one can easily conclude that it is preferable to use it instead of the widely and long-known YaMZ-236.
If you decide to put a KAMAZ gearbox with a divider, then the speeds will be as follows.
At 10, the increased speed will be 89.54 km / h.
If we got a YaMZ-238 gearbox 12 Fas Gear with a flywheel casing, then we will count again to get the result.
View of the checkpoint 12-speed FAS GIR.
If we found and installed an eight-speed gearbox V 8 with Renault, then by counting the table we get the following results.
Let's look at the maximum speed with this checkpoint, it = 96,70 km / h.
If we put the checkpoint B-9, we get the following table. In principle, the B-9 differs from the B-8 gearbox only by the addition of a creep gear.
Accordingly, the maximum speed from the V-9 checkpoint will also be equal to 96.70 km / h.
If we adjust the B-18 checkpoint, we will get the following results.
As you can see, such a gearbox with a large range and 18 gears allows you to accelerate the car to 111,59 km / h.
If we decide to install a ZF-8 or ZF-9 gearbox, then the difference will again be in addition to the creep gear ZF-9 gearbox.
Let's calculate the speed at the checkpoint 9S1310TO,
The maximum speed of these checkpoints will be the same and equal 96.70 km / h, but the ZF-8 will not have a creep transmission.
External view of the gearbox ZF 16S 1820 TO /
We make a table of speeds for this checkpoint.
As you can see from the table, the maximum speed will be 86.35 km / h.
Tell me who has come across, what are the pros and cons of an eight-step box with a long divider from a short divider
Vladimir (Dyson) nothing, both shit, ak and any Mazovian checkpoint
Alexander (Naarah) And what a way out, what to put then you can
Vladimir (Dyson) Alexander, zf or america 10 or 13 mortar
Alexander (Naarah) Duck gearbox probably costs the same as the car itself
Vladimir (Dyson) Alexander, but forever, and not as a Mazovian every year to do 3 times
Alexander (Naarah) As far as I understand, you did it, but there are many alterations?
Vladimir (Dyson) Alexander, what is your grip?
Alexander (Naarah) I can’t say which, dv 238 turbir. box 8 with a small divider, all from the factory, not changed yet
Vladimir (Dyson) Alexander, what year?
Vladimir (Dyson) Alexander, well, there should be a single-disk, the gearbox itself fits, but the nylaps need at least 202 boxes
Alexander (Naarah) And at the price you can't tell what to expect from such a rework
Vladimir (Dyson) Alexander, but there is, in principle, not a lot of the front end, the maximum glass will need to be changed, it costs a couple of rubles, the checkpoint itself for 70 thousand can be found well, and a thousand little things by 3-4, I think no more
Yuliana (Yada) Guys Got A Difference In Mazov Box 8 With Short And Long
