DIY kamaz clutch repair

The clutch of KamAZ-4310, 55111, 43118, 5320 vehicles must be replaced:

- Slipping of the clutch discs as a result of weakening or breakage of the pressure springs, wear of the friction linings of the driven discs, in which it is impossible to restore the free play of the clutch release shaft lever by adjusting.

- Incomplete disengagement of the clutch as a result of skewing or warping of driven and pressure discs, as well as loosening of the rivets of the driven disc hub.

- Mechanical damage to the clutch, impairing its normal operation.

Removing the clutch of cars Kamaz-4310, 55111, 43118, 5320

- Remove the gearbox, carry out without draining the oil from the gearbox housing.

- Screw the four technological bolts into the pressure plate until they stop in the casing. Bend back the tabs of the lock washers.

- Unscrew the bolts securing the clutch cover to the flywheel and remove the clutch cover with the pressure plate assembly, the middle and driven clutch plates.

Clutch installation KamAZ-4310, 55111, 43118, 5320

- Insert the driven and middle discs into the flywheel cavity.

Technical condition - Correct location of driven disc hubs - with short protruding ends towards each other

Align the holes on the clutch cover with the holes in the flywheel.

- Insert the gearbox drive shaft into the spline holes of the driven disks Kamaz-4310, 55111, 43118, 5320, insert the casing mounting bolts and tighten them. The tightening torque of the bolts is 53.9–61.8 nm (5.5–6.3 kg / cm). Tighten the bolts evenly in 2-3 steps

Specifications - Before installing the clutch cover KamAZ-4310, 55111, 43118, 5320 with a pressure plate assembly, check the correct position of the thrust ring

To check the pressure plate assembly, install and secure to a test stand or flywheel with an insert, providing a mounting dimension of 29 ± 0.1 mm, and loosen the process bolts. The correct position of the thrust ring is determined by the mounting dimension 54 ± 0.3 mm, the runout of the ends is not more than 0.2 mm.

- Unscrew the process bolts and take out the slotted mandrel

- Install the gearbox.

Fig. 1. Clutch disc KamAZ-4310, 55111, 43118, 5320 pressure

1 — pressure clutch disc; 2-ring persistent pull-off levers; 3 - pull-back lever; 4 - needle roller of the levers and forks of the levers; 5 - the axis of the lever fork; 6 - persistent ring; 7, 19 - washers; 8 - lever fork; 9 - spring of the thrust ring; 10 - pull-back lever with fork and spring assembly; 11 - spring loop; 12 - clutch cover; 13 - nut of the lever adjusting fork; 14 - lock washer; 15 - support plate; 16 - locking plate; 17 - bolt; 18 - tie bolt; 20 — clutch pressure spring; 21 - lining washer; 22 - pressure spring lining

Dismantling of the clutch mechanism KamAZ-4310, 55111, 43118, 5320

- Install the clutch cover assembly with the pressure plate on the stand and secure

- Bend back the tabs of the locking plates 16 (Fig. 1), unscrew the bolts 17 fastening the locking and supporting plates and remove the supporting 15 and locking 16 plates

- Remove the lock washers 14 of the adjusting nuts and unscrew the adjusting nuts 13

- Mark the relative position of the casing 12 and the pressure plate

- Remove the pinch bolts 18 from the pressure plate 1 and remove the clutch cover 12 from the stand

- Remove the thrust washer 2 of the release levers and the hinges 11 of the spring of the thrust washer

- Remove the pressure springs 20, washers 21 and washers 22 from the clutch pressure plate

- Remove the thrust washers 6 and flat washers 7 from the axles 5 of the lever, pressure plate

- Press out the axles 5 of the forks of the pressure plate levers, remove the levers 10 complete with forks 8 and springs 9 of the thrust "ring and take out the needle rollers 4 of the release levers 3

- Remove the pressure plate from the stand

- Press out the axles 5 of the forks of the levers, remove the springs 0, disconnect the forks 8 from the levers 3 of the pressure plate, remove the needle rollers from the holes of the levers

Fig. 2. Driven clutch disc KamAZ-4310, 55111, 43118, 5320

1 - rivet; 2, 4 - friction clutch pad; 3 - driven clutch disc, assy

- Install the driven disc assembly on the press, press out the rivets 1 (Fig. 2) fastening the friction linings to the clutch disc and remove the friction linings 2 and 4 from the driven disc

- Place the middle drive disc 1 (fig. 3) on the workbench

- Bend the edges of the lock washers 2, unscrew the axles 6, remove the bushing 5, the release lever 4 and the spring 3

- Wash the parts of the middle drive disc and check their condition

Fig. 3. Clutch disc KamAZ-4310, 55111, 43118, 5320 medium leading

1 - medium drive clutch disc; 2 — lock washer; 5 —spring; 4 - release lever; 5 - bushing of the release lever; 6 - axis of the release lever

Specifications for flaw detection and repair of parts of the clutch mechanism KamAZ-4310, 55111, 43118, 5320

Fig. 4. Pressure disk Kamaz-4310, 55111, 43118, 5320

Pressure disk Kamaz-4310, 55111, 43118, 5320 (Fig. 4). Not allowed:

- non-flatness of the friction surface A more (0.07 mm);

- wear of the friction surface under the release levers more than 0.5 mm;

- cracks on surface A (thermal, radial) with a depth of more than 0.5 mm;

- the width C of the slots for the clutch pressure plate levers is more than 12.2 mm;

- diameter B of the holes for the lever axle of the clutch pressure plate is more than 10.85 mm;

- the width E of the spikes is less than 59.64 mm.

Needle rollers. Traces of corrosion and dents on the surface of the needle rollers are not allowed.

Fig. 5. Clutch cover KamAZ-4310, 55111, 43118, 5320

Clutch cover KamAZ-4310, 55111, 43118, 5320 (Fig. 5). Not allowed:

- wear of the guide surfaces A under the pressure springs to a wall thickness of less than 5 mm; local wear of the guide surfaces 0.6 mm, no more;

- thickness B on spherical surfaces for adjusting nuts is less than 3.2 mm.

Fig. 6. Driven disk Kamaz-4310, 55111, 43118, 5320

Driven disk Kamaz-4310, 55111, 43118, 5320 (Fig. 6). Not allowed:

- the beating of the friction surfaces A and C when centering on the lateral surfaces of the slots is more than 0.5 mm;

- the width of the depressions D of the spline hole of the hub is more than 6.1 mm;

- wear of the friction lining to the rivets.

Discs are subject to repair for the following defects:

- weakening of the rivets of fastening of the friction linings, removable by replacing the rivets;

- breakage, cracks, burning or wear of the friction surfaces of the linings, eliminated by replacing the friction linings.

Fig. 7. Clutch disc KamAZ-4310, 55111, 43118, 5320 leading average

Middle drive disk Kamaz-4310, 55111, 43118, 5320 (Fig. 7). Not allowed:

- the width A of the thorns is less than 59.52 mm;

- thermal radial cracks on friction surfaces C and B with a depth of more than 0.3 mm;

The middle drive disk Kamaz-4310, 55111, 43118, 5320 must be repaired with the following defects:

- warping, scuffing and uneven wear of surfaces C and B of the disc, eliminated by grinding the disc to a thickness of at least 24.56 mm.

Assembling the clutch mechanism KamAZ-4310, 55111, 43118, 5320

- Install needle rollers 4 into the hole of the pull-off levers 3 (see Fig. 1) using the technological pins, connect the levers 3 with the forks 8, press in the axles 5 of the levers, put the springs 9. Put on the flat washers 7 and lock washers

- Place the needle rollers in the holes of the release levers

- Insert the release levers 10, complete with forks and springs, alternately into the slots of the pressure plate bosses, insert the axles 5 into the aligned holes of the bosses and levers, pushing out the technological pins, and install the lock washers

- Install on the pressure plate KamAZ-4310, 55111, 43118, 5320 washers 22, washers 21 and pressure springs 20

- Fit the hinges 11 of the thrust washer springs and the thrust washer 2

- Install the clutch cover 12 on the pressure springs, align the ends of the forks 8 with the holes in the cover 12, compress the pressure springs by screwing the tensioning bolts 18 into the pressure plate.

- Screw the adjusting nuts 13 onto the lever forks

- Check the position of the thrust washer 2 and adjust if necessary. Before adjusting, ensure the installation dimension from the friction surface of the pressure plate 1 to the casing flange 12, equal to 29 ± 0.1 mm, and then loosen the tie bolts 18.

Determine the correct position of the thrust ring 2 with the installation dimension from its friction surface to the friction surface of the pressure plate 1, equal to (54 ± 0.3) mm. Face runout of ring 2 should be no more than 0.2 mm.

If the position of the thrust ring is violated, adjust the adjusting nuts 13, restoring the indicated size, and then screw in the tie bolts 18.

- Install the lock washers of the 14 adjusting nuts

- Install the support 15 and lock 16 plates of the adjusting nuts, screw in the bolts 17, lock the bolts by bending the tabs of the lock plates 16, lock the adjusting nuts 13 by bending the lock washers 14.

- Remove the clutch cover KamAZ-4310, 55111, 43118, 5320 assembled with a pressure plate from the stand

- Align the holes of the friction pads 2 and 4 (see Fig. 124) with the holes of the clutch driven plate 3 and press the pads against the disc with a clamp

- Insert rivets 1 into the aligned holes of the linings and disc, place the disc on the press support and rivet the rivets

- Turn the driven disc assembly over, insert the rivets into the holes, place the disc on the press support and rivet the rivets.

- Check the correct assembly of the clutch driven disc KamAZ-4310, 55111, 43118, 5320. The thickness of the driven disc assembly with linings is 11 ± 0.1 mm. The non-parallelism of the friction surfaces of the driven disc assembly is no more than 0.2 mm. 3. The runout of the friction surfaces of the fixed linings should be no more than 0.5 mm at a radius of 137 mm from the center of the disc.

- Apply a thin layer of grease to axle 6 (see Fig. 3)

- Place bush 5, lever 4, spring 3 on axle 6, lock washer 2

- Screw the axles with levers into the middle drive disc 1. After screwing in the axles, the lever

should rotate freely around the axis by hand and, under the action of a spring, return to its original position.

- Lock the axles of the middle drive disc by bending the lock washer 2 on both sides

- Check the correct assembly of the middle drive disc

KamAZ and MAZ are vehicles that have gained particular popularity due to their exceptional reliability. They are used literally in all spheres of life - cargo transportation, construction, the agricultural complex, often even off-road races are arranged at KamAZ trucks. Time-tested quality will not let you down if you use it correctly and service the components and assemblies on time. Specialists advise to pay special attention to such procedures as adjusting the clutch of MAZ and KamAZ. In the event of any malfunctions, the KamAZ clutch basket changes in a very short time. Let's see why the clutch of MAZ and KamAZ requires special attention.

As a rule, a dry two-disc (in rare cases single-disc) clutch of a friction type is installed on KamAZ vehicles. This device is common in almost all heavy machines with great power. It requires constant maintenance due to the fact that at the time of operation, due to the great power of the cars, these clutches experience colossal loads. So, in what cases does it become necessary to adjust the clutch of Maz and KamAZ:

• The device clearly slips at high revs.
• Free travel of the pedal does not correspond to the standard values.
• Mechanical crackling sound occurs when shifting gears.

If you notice even one of the listed signs, it means that the KamAZ clutch basket requires adjustment. If this is not done in time, problems can spill over to the gearbox and other transmission parts. In general, competent adjustment of the Kamaz clutch can be divided into 3 main stages:

If these procedures are additionally performed periodically with adjustment, then the device will last much longer.

• Stretch the bolts that secure the clutch booster.
• device for smudges. If found, find and eliminate the leak, then bleed the system so that air comes out of it.
• Evaluate the operation of the pedal springs and the shaft arm. If faulty is found, replace them.
• Lubricate the coupling bearing and the yoke shaft sleeve of the device.
• Assess the liquid level in the expansion tank. Top up if necessary.

Clutch adjustment KamAZ

It is very problematic to cope with all these works for the first time. If you are not confident in your abilities. Entrust the adjustment to specialists and follow the progress of the work. Having memorized all the steps in practice, in the future you can easily adjust the device yourself.

There are times when adjusting the clutch will no longer correct the problem. Perhaps you missed the moment when it was possible to get by with small forces, or maybe the device failed for some objective reason. So, it's time to change the grip of the oil if you notice the following signs:

• The device turns on abruptly, the car jerks and jerks off abruptly.
• Noise in the mechanism, possibly a loud crackle when engaging a gear.
• The car starts with a delay, even if you release the clutch in time.
• The characteristic burning smell in the cabin (this is a clear sign that the clutch has burnt out).

It is not worth tightening with replacing the clutch. As a result, everything can end with damage to the gearbox or the fact that one day the car simply will not be able to move.

It is worth taking on work on your own only if you know exactly the sequence of actions. Otherwise, it is better to consult a specialist.

However, if you are confident in your abilities or you are familiar with the KamAZ clutch basket, you can get down to business.

Before starting work, you need to stock up on a certain set of tools. So, you will need:

1. A set of wrenches or socket heads.
2. Emphasis.
3. A ruler to measure the pedal free travel later.
4. Pliers and pliers.

If you have all this, it's time to get to work. The main thing is to strictly follow the entire sequence of actions:

• Remove the transmission first. For KamAZ, it is very heavy, so you will need the help of several people.
• Further, the next step is the clutch basket, we also remove it.
• Then remove the clutch discs driven, middle and leading.
• Then replace them with new parts of the device. Begin by installing the first driven disc and then install the parts in the reverse order to disassembly.
• Once again, make sure that the device is assembled correctly and everything - you can put the gearbox in place.

If the clutch is a single disc, the process is similar and even easier. It may seem that everything is quite simple, but this is far from the case. Replacing and adjusting the clutch oil will require a lot of physical effort and time. Perhaps it makes sense to trust the specialists, who will do everything competently and without mistakes. By observing the process, you will be able to memorize the entire sequence in practice, and the next time you will start adjusting or replacing the device yourself.

There are several simple rules to extend the service life of a KamAZ clutch. Unfortunately, not all drivers use them and often, the device has to be changed much earlier than provided by the manufacturer.

1. Do not keep the mechanism wrung out for too long. Using clutch slip at traffic lights and slowing down is very harmful to the device.
2. And, most importantly, check the pedal free play as often as possible and lubricate all available clutch assemblies. This is probably the most important guarantee that you will not have to think about replacing the mechanism for at least several years.

• How to replace a clutch at KamAZ?
• Reasons why you need to change the clutch of KamAZ
• Replacement tool kit
• Stages of replacing the KAMAZ clutch
• Dismantling the gearbox
• Removing the clutch basket
• Removing the clutch discs
• Replacement and assembly of parts
• How to extend the life of a KAMAZ clutch

The clutch performs the function of transmitting torque using friction and sliding forces. The mechanism provides smooth switching of the speed mode, the ability to get under way without jerking to a complete stop.In this article, we will consider the malfunctions and the sequence of replacing the KamAZ clutch with our own hands.

A heavy load on the KamAZ body, bad roads, a large number of vehicles and sharp maneuvers lead to wear of the clutch elements, and sometimes to the replacement of the clutch at KamAZ.

To prevent a breakdown from catching you on the road, listen to the car. You can hear a loud crackle when changing gears - this indicates breakage of springs and wear of gaskets... In case of a sharp turn on and jerks from a place, it is worth checking the damper and the spring of the fork. The characteristic smell of burnt rubber and the slipping of the car indicate the necessary replacement of the gaskets. All clutch parts are interconnected, so the unusual behavior of the car should immediately alert you. It is not worth delaying the elimination of breakdowns and replacement of the KamAZ clutch. Otherwise, one day he simply will not move.

Prepare the instruments before proceeding with the technical procedures. So, a set that you may need for disassembling, replacing and installing a two-disc clutch on KamAZ:

• Wrenches and sockets in different sizes.
• An emphasis, a set of screwdrivers, a center punch.
• Metal ruler.
• Pliers, pliers and rags.
• Jack.
• Hoisting device (hoist).

To replace the clutch on KamAZ with your own hands, you will need assistants to remove the gearbox.

Perform the process in the following steps:

1. Unscrew the fastening nuts, and disconnect the universal joint, then the pneumatic hydraulic booster. Release the starter from the mount.
2. Further, in turn, the tubes to the reduction gear and the gear lever.
3. For further work, you will need a jack.
4. Install the device under the engine pan and lift the power unit.
5. Remove the rear yoke and spacer bar.
6. Release the bracket from the mount.
7. Secure and tighten the hoist.
8. Next, remove the side cushions of the power unit. Unscrew the box mount to the engine.
9. Using a hoist, move the gearbox from the engine to the input shaft exit and remove it.

The clutch basket on KamAZ consists of a flywheel (drive disc), a pressure plate and a protective casing. The driven part is made of steel discs that dampen vibrations.

In order to remove the clutch box, screw four bolts into the pressure plate, pressing it into the casing. Use a pair of pliers to gently squeeze the tendrils of the lock washers. Then remove the cover mount to the flywheel and remove the clutch cover and discs alternately.

The clutch on KamAZ is a two-disc friction, with pressure springs, has a device for automatically setting the middle drive disc to the middle position.

When removing the flywheel, take into account the peculiarities of its design: the middle drive disk stands in the grooves of the flywheel located along its circumference. To ensure heat dissipation and ventilation in the clutch, holes are provided in the "body" of the disc, separated by ribs (spikes). There is a lever in the spikes that regulates the position of the middle drive disc. The pressure plate, like the middle drive one, is installed in the grooves of the flywheel on the spikes. On one side of the disc there are tabs for installing pressure springs. Remember the order of their location. The driven disc consists of: a hub, rivets, a spring, linings and a torsional vibration damper (damper). The hub with the disc is not rigidly connected, only eight springs. Release springs and an intermediate disc adjusting bolt are located between the driving and driven discs.

Replacing and installing clutch discs on KamAZ is not a complicated process.

Frequent damage to the clutch pressure and clutch discs are cracks on the surfaces of both discs and linings, complete wear of the linings and rings, disc deformation, loosening of the hub fastening, scoring on the smooth surfaces of the pressure and middle discs, damage to rivets. In order to replace the worn-out gaskets with new ones, you need to remove the old rivets. Replace worn-out discs with new ones.

Not all car owners know how to properly install clutch discs on KamAZ. Let's consider the sequence of actions.

We put the first driven disc with the long end of the hub towards the engine. The second - we put the long end of the hub to the gear basket. Balance the discs before tightening the basket.

In order not to struggle with the question of how to put disks on KamAZ for several years, remember a few rules for the correct operation of the machine. Do not keep the clutch pedal depressed to the floor for a long time - this will wear out the springs. At traffic lights or to reduce speed, many drivers "slip", this is a detrimental manipulation for the entire mechanism. Another tip concerns the timely lubrication of all accessible parts of the device. Not all drivers, even knowing these recommendations, use them, which leads to frequent repairs of the KamAZ clutch.

It is necessary to adjust the clutch on KamAZ 5320 and other models to maintain the good condition of the truck. Sometimes the need to carry out such work may arise on the way, so it is desirable for the driver of the car to know the basic conditions for independently and correctly performing the setting of the mechanism.

On the bulk of KamAZ trucks, a double-disc clutch with a radial arrangement of power springs is used. To operate the mechanism, a hydraulic drive with a pneumatic amplifier is used. This arrangement significantly reduces the effort required to press the clutch pedal. During the operation of KamAZ, the clutch discs wear out, which must be compensated for by adjusting. Correct adjustment of the mechanism ensures the fuel consumption declared by the plant and confident acceleration of an empty or laden vehicle.

Diagram of the KAMAZ clutch drive mechanism

The main components of the drive, which is shown in the photo, are:

• pedal (1);
• hydraulic unit (2) with reservoir (3);
• highway (6);
• executive pneumatic cylinder (16).

The clutch of KamAZ models 55111, 5320, as well as 43118 and 740 consists of the following structural units:

• clutch housing (A);
• clutch disc with stamped metal casing (B);
• pressure springs (B) and levers (D);
• one master drive (E);
• two driven discs (D) with lining (F).

Clutch diagram KamAZ 740 with a diesel engine

Driven discs in the clutch structure of a KamAZ truck are made using heat-resistant friction linings, which allow for a long service life of the mechanism. The design of the discs provides a damper for vibrations arising from the rotation of the motor shaft. The drive pedal is mounted on special bushings and rarely requires lubrication during operation.

On more modern KamAZ models, single-disc clutches of the so-called Euro type are used. This mechanism is, for example, on models 6520 or 4308. The supplier of the elements of such assemblies is Sachs, and amplifiers made by Wabco are used. There are several models of clutches that differ in the amount of transmitted torque. One of the differences between imported amplifiers is the built-in friction lining wear indicator. Wear measurement is carried out by the distance between the amplifier housing and the washer on the rod. With full wear of the linings, this distance is in the range from 23 to 25 mm. Driving the car in this case is still possible, but it is urgent to carry out repair work.

CCGT unit Wabco, in the upper left part you can see the wear indicator rod

On some models of KamAZ, for example, on 43114, there may be a CCGT produced by the Volchansk plant of auto-units, in which there is no possibility of adjusting the stem. Typically, such a CCGT is either replaced with an adjustable one or a different stem is installed with the ability to adjust.

If there is a problem with the clutch, it is necessary to try to make an adjustment.When discs slip (sluggish acceleration, a slight burning smell), it is necessary to set the correct clutch travel.

In case of incomplete separation of disks (difficult switching), more operations will have to be performed:

1. Set the pedal travel.
2. Remove airiness from drive lines.
3. Check the liquid level in the CCGT unit.

When using the Euro unit, only the pedal free travel needs to be adjusted. Lubrication and adjustment of the rest of the clutch parts during the operation of the machine is not provided, except for monitoring the height of the fluid level in the drive reservoir.

Clutch adjustment on KamAZ 5320 and other models means setting the correct clearance between the plane of the release disk and the lever heads, as well as setting the pedal and drive clutch free travel. The permissible free travel for the clutch pedal must be between 6 and 12 mm.

The gap is understood as the distance between the points of the central part of the pedal pad when released and at the moment the master cylinder starts to turn on. Free travel is adjusted by rotating the eccentric pin, which is in the connection of the pedal lever with the upper eye of the amplifier linkage. The adjustment is made with the pedal tension spring fully depressed, that is, the pedal should rest against the upper rubber buffer, which serves as a travel stop.

For example, on KamAZ 65115, the do-it-yourself adjustment process is as follows:

1. Loosen the cotter pin of the castle nut.
2. By rotating your finger, you need to achieve an acceptable free play.
3. Tighten the nut and lock it with a cotter pin.
4. Check the full pedal travel. If everything is adjusted correctly, then it should be in the range from 185 to 195 mm.

On single-disc MFZ units, the adjustment is carried out in the same way, but the pedal travel should be between 140 and 150 mm.

The process of adjusting the free wheeling is shown below using the example of KamAZ 4310, the author of the video is Vladimir Krasikov.

The next step in the adjustment will be to adjust the parameters of the free play of the clutch, the value of which should be between 3.2 and 4 mm. The measurement is carried out by turning the adjusting nut.

The sequence of actions in this case:

1. Loosen the yoke fixing nut.
2. Unpin the fastening pin, make it move freely and remove it.
3. Rotate the traction fork until the required clearance is obtained.
4. Tighten the nut and fit the pin.
5. Install the locking pin.
6. Check the setting. When the pedal is fully depressed, the clutch travel must be at least 25 mm.

Before starting the debugging of the mechanism, it is necessary to find out the length of the pusher stroke. To do this, disengage the clutch completely and measure the stroke. If its value is 25 mm or less, then the clutch will not be completely disengaged. The driver will notice such a problem immediately on the difficult gear selection. To find the causes of the problem, it is necessary to check the level of the working fluid in the pusher cylinder. The standard volume is 380 cubic meters. see If the level of the substance is insufficient, add it.

Hydraulic system diagram

On the example of the KAMAZ 5511 model, adding fluid is performed as follows:

1. Open the lid of the reservoir located on the drive housing.
2. Add liquid to a level 15-20 mm below the edge of the neck.

A second reason for poor amplifier performance can be air in the system. In this case, the drive system must be bled. This procedure is somewhat more complicated.

On KamAZ 55102, this requires:

1. Add liquid to the normal level.
2. Remove the protective cap from the bypass valve (installed on the CCGT body), put on a rubber hose and lower it into a container with liquid.
3. Sharply push the clutch pedal all the way down.
4. Open the valve one turn and press the pedal until the bubbling of the substance at the outlet from the hose stops. In this case, it is necessary to constantly pour new fluid into the supply tank, preventing it from falling below the 40 mm mark from the top of the tank.
5. Close the valve, remove the hose and replace the cap.
6. Add liquid to the working level.
7. To control the quality of work, it is necessary to press the pedal all the way - the pusher travel should not be less than 25 mm.

Clutch basket adjustment refers to the adjustment of the feet placed on the basket. Such debugging can be performed with the box removed or adjusted directly on the car.

When completing the task without removing the box, you will need a homemade tool, which is a 3.5 mm wire with a 20 mm end bent at a right angle. With the help of such an improvised probe, the gap between the release bearing and the support ring of the clutch legs is checked. The clearance is adjusted with a nut on the CCGT rod. The lugs can be brought to the ring through the hatch in the upper part of the clutch housing. In this case, it is important to ensure the most uniform fit of the legs to the surface. But it is more correct and more reliable to regulate the clutch removed from the motor.

1. Place the assembled pressure plate on a template that provides a clearance of within 29 mm.
2. Loosen the mounting bolts.
3. Set the position of the foot stop ring. All four feet should touch the ring at the same time.
4. Check the runout of the working surface of the disc.
5. Lubricate the front bearing located in the crankshaft.
6. Install the clutch using a mandrel, which will ensure the alignment of the mechanism discs and the engine shaft.

This adjustment is carried out only with a two-disc clutch. The unit with one disc does not need such adjustment.

The video from the Auto and Moto channel shows the removal of the clutch and the design features are clearly visible, as well as the drive for the operation of the mechanism.

In addition to adjustments, the clutch of KamAZ vehicles needs regular maintenance, since this significantly increases the service life and reliability of the mechanism on all brands of KamAZ.

On the example of model 53215, maintenance consists of the following main points:

1. Checking the tightening of the booster mounting bolts in the clutch drive chain.
2. Monitoring the tightness of hydraulic lines. They should be free of any oil stains.
3. General check of serviceability of parts of the pedal assembly. All elements must be in complete condition and not have large backlash in the joints.
4. Checking for the presence of grease in the coupling bearing and the bushing of the fork connection. There are three points for the oil supply in the clutch housing, equipped with grease fittings. They are injected with oil using a syringe.
5. Draining condensate from the CCGT housing.
6. Control of the fluid level in the amplifier reservoir.

If all the work performed does not lead to the restoration of the clutch mechanism, then this becomes one of the signals for its replacement.

Other signs of critical wear of structural elements are:

• a sharp turn on of the disks, while a hard jerk of the car occurs;
• difficult inclusion of all gears, accompanied by a characteristic crackle;
• sluggish acceleration of the car, while the engine speed clearly does not correspond to the selected gear and speed;
• the smell of burning linings when driving.

If such problems appear, it is necessary to stop driving as soon as possible and repair the mechanism. Further operation of the car with faulty or burnt out clutch discs will lead to failure of the gearbox.

The photographs below show some elements of the clutch drive system of a KamAZ truck.

The video filmed for the Auto and Moto channel demonstrates the adjustment of the clutch installed on the KamAZ 740 diesel engine.

To replace the clutch on your own, you will need assistants to remove the gearbox.

The order of work:

1. Unscrew the fastener nuts, remove the universal joint, pneumatic hydraulic booster, release the starter from the fastener.
2. Remove the tubes for the reduction gear, as well as the gear lever.
3. Take a jack.
4. Place a jack under the engine pan, raise the engine.
5. Remove the rear cross member as well as the spacer bar.
6. Free the bracket from the mount.
7. Fasten the hoist and tighten.
8. Remove the engine side mounts. Unscrew the gearbox fasteners to the motor.
9. Using a hoist, move the gearbox away from the engine until the input shaft comes out, then remove it.

Do-it-yourself repair of the KAMAZ clutch basket means its removal. It includes a flywheel, a pressure plate and a guard. The driven part is steel discs that damp vibrations.

Repair of the KAMAZ clutch basket requires its preliminary removal. To do this, screw 4 bolts into the pressure plate and press the disc into the casing. Using the pliers, gently squeeze the antennae on the lock washers, then remove the elements with which the casing is attached to the flywheel, then remove the discs and the clutch cover in turn.

Before carrying out the repair of the KAMAZ clutch and removing the clutch basket, it is necessary to mark the location of the basket and the flywheel with the help of a core.

Replacing the KAMAZ clutch disc requires its removal. KAMAZ has a friction 2-disc clutch, pressure springs and a device for automatically giving the middle drive disc a middle position.

When removing the flywheel, it is necessary to take into account the specifics of its design: the leading middle disc is installed in the flywheel grooves, which are located around the circumference of this disc. To ensure heat dissipation in the clutch and its ventilation, the disc in its "body" has holes that separate the ribs (spikes). These cleats have a lever that adjusts the position of the driving middle disc. Both the pressure and the driving middle discs are located on the spikes in the grooves located in the flywheel.

The other side of the disc has projections that are designed for pressure springs. You should remember the order in which they are placed. The driven disc includes a hub, a spring, a rivet, linings, a torsional vibration damper. The hub with the disc has no rigid connection, there are only 8 springs. The space between the driven and driving discs is the location of the release springs, as well as the adjusting bolt of the intermediate disc.

Installation and replacement of a two-disc clutch at KAMAZ is a simple process. Common types of damage to the driven and pressure discs are cracks on their surfaces, on linings, wear of rings and linings, disc curvature, deterioration of the hub fastening, damage to rivets, scoring on disc surfaces. Replacing used gaskets with new ones requires removing old rivets. Discs that have become unusable must also be replaced.

Not every car owner knows how to properly install clutch discs on KAMAZ. There is a certain order of actions.

The first of the driven discs is installed with the long end of its hub to the motor, and the second - by the same end to the gearbox. The discs must be balanced before tightening the basket.

In the course of the wear of the linings on the driven discs, as well as their replacement, the clutch drive, as well as the clutch free play, should be adjusted.

Repair of the KAMAZ clutch cylinder should be carried out after the problem with the tightness of the CCGT unit and its pumping has been eliminated.

After bleeding is complete, depress the clutch pedal, turn the air release valve until it stops, and then remove the hose from the valve head and put on a cap for protection.

The correct liquid level is then established inside the master cylinder. Repair of the KAMAZ clutch master cylinder and replacement of the KAMAZ clutch master cylinder imply this operation as mandatory. Brake fluid released from the hydraulic system during pumping can be used again after it has settled and further filtered. The quality of the pumping performance is determined by the magnitude of the stroke of the pusher of the pneumatic hydraulic booster.

It is necessary to check for condensation inside the power cylinder of the pneumatic hydraulic booster. To drain the condensate, you need to unscrew the plug of the aluminum housing of the pneumatic power steering.To completely drain, lightly depress the clutch (pedal).

At least once every 3 years, flush with methanol or brake fluid of the hydraulic system in the clutch drive, disassemble the master cylinder and pneumatic hydraulic booster, and fill with fresh brake fluid.