The KAMAZ gearbox is a rather complex vehicle mechanism through which torque is transmitted to the drive wheels. Transmission from the engine to the gearbox occurs through a cardan. During work, he experiences incredible stress. The most basic property of a gearbox is the ratio of the teeth of the driven gear to the number of teeth of the drive gear.
The KAMAZ vehicle has several modifications. There is just a rear-wheel drive car, but there is also an all-terrain vehicle. Based on this, there are gearboxes, rear, middle and front. They have certain differences, but the principle of operation is the same. We will focus on the KAMAZ axle gearbox in general terms.
- We sell gearboxes and share useful information.
Price for KAMAZ gearbox
How the KAMAZ gearbox works
As mentioned above, a gearbox is a complex mechanism. We will not consider in detail all spare parts of the gearbox. The main role is played by gears and bearings. They are located in the final drive housing. The KAMAZ axle gearbox takes on heavy loads and is located in constant rotation. Gears and bearings cannot work for a long time without lubrication. To ensure normal operation, oil is poured into the crankcase box. The oil level is measured in the following way. The crankcase cover is opened and filled until it begins to flow out of the hole.
Main gearbox malfunctions
The KAMAZ gearbox is a very reliable mechanism. He is not susceptible frequent breakdowns, if preventive measures are carried out in a timely manner. Despite the reliability of the gearbox, malfunctions can occur at any time. Several of the most common faults are highlighted.
- strong heating of the main gear
- loud gearbox noise
- oil level constantly drops
Strong heating of the main gear can occur due to a lack of oil in the crankcase; you need to add it to the required level. The bearings are too tight, they need to be loosened a little. The gears are not adjusted correctly and need to be adjusted.
The KAMAZ gearbox makes a lot of noise; this can occur for various reasons. The bearings have become unusable. Faulty bearings need to be replaced. The gears are too worn out or incorrectly adjusted. Adjust or replace worn out gears. The nuts that secure the bearings are loose and need to be tightened.
If the oil level goes down, the following problems may occur. The oil seal on the input shaft has failed and needs to be replaced with a new one. Dirt has clogged the breather, you need to clean it.
Measuring the level and changing the oil in the KAMAZ gearbox
Measuring the oil level is a fairly simple procedure. Unscrew the control hole nut and add oil until it is level with the control hole.
Changing the oil is a more difficult job. You need to jack up the rear truck. For safety, install wheel chocks. Unscrew the drain and control plugs. After the oil has drained, replace the drain plug. Fill in the flushing fluid; if you don’t have it, use diesel fuel. Let the engine run for a few minutes in third gear. Drain the liquid and add fresh oil. Tighten the inspection plug and lower the jack. The KAMAZ gearbox is ready for further operation.
Our company is pleased to offer you an original KAMAZ axle gearbox at the best price, please contact the sales department.
KAMAZ medium gearbox is filled with 7.8 liters (0.80 liters in the differential and 7 in the crankcase itself).
To the KAMAZ rear gearbox respectively - 7. The main sign of lack of oil is the appearance of a hum. Don't let it come to this.
Oils suitable for KAMAZ gearboxes and final drives
Very often, drivers operating KAMAZ vehicles ask the question of what type of oil is suitable for the normal functioning of the KAMAZ gearbox. We can talk about this topic for a long time, but in general we can recommend proven brands of oils at a price corresponding to the available means.
The best option would be to give preference to 75W-90 or 80W-90 gear oil from any well-known brand, the main thing is that the oil is original. Prices for imported motor oils are slightly higher than for domestic ones, but we recommend the following:
Castrol Syntrax Long Life (75W-90) - this product is a completely synthetic oil for truck gearboxes, most suitable as a lubricant for the main transmission of vehicles with a large load. It has excellent technological parameters and a long service life.
Shell Spirax S6 AXME (75W-90) is a multi-purpose, fully synthetic, fuel-efficient axle oil designed to be used in axles, has a long service life and is capable of providing the best protection for the latest heavy-duty axles. Thanks to special anti-friction properties and excellent flowability, it significantly reduces power losses and the temperature of units, while increasing the efficiency of the vehicle.
MOTUL Motylgear-75W-90 is suitable as an oil for heavy-duty gear shift mechanisms, axles with hypoid-type mechanisms without automatic locking and low-slip mechanisms. Produced according to the standard: API/GL-4 and GL-5, MIL L-2105D
Mobilube-HD80W-90 is known as an oil produced from similar high-quality products and enhanced with a number of additives that provide maximum effect and is intended for components operating under high loads. The model of this oil is designed for use in trucks, the components of the operating vehicles of which are subject to increased pressure and shock loads. Promotes excellent performance of nodes requiring API level and GL-5.
The most common transmission fluid TAD 17 is a universal mineral-type transmission oil for any season, used to lubricate components of trucks and other vehicles operating under extreme loads. This analogue is perfect for KAMAZ axle reducer .
Supplied with a range of highly effective multifunctional additives. This oil is used to lubricate transmissions of all types. This liquid contains residual oil products obtained during the processing of fuel oil. TAD - 17 is capable of creating a durable oil coating that creates ideal operating conditions in heavy duty conditions and maintains performance and properties within temperature limits from minus-25 degrees Celsius to plus-130 degrees Celsius.
EssoGear Oil GX-75W-90 - this oil is partly synthetic, designed for any season and is used to lubricate transmissions in heavy-duty new units, in particular, for hypoid-type gears and specialized gearboxes designed in a stepped type.
This article will focus on the gearbox. You will learn: what it is, what are the typical malfunctions associated with it, and how they can be prevented. We will dwell in more detail on the process of repairing the KAMAZ gearbox and the features of caring for this mechanism.
- This is a mechanism that experiences incredible loads when moving. It is on his “shoulders” that the most difficult work falls - transmitting torque from the driveshaft to the wheels. How does this process happen? What problems can arise with the KAMAZ gearbox?
KAMAZ gearbox - definition and purpose
A gearbox is a mechanical device that serves to transmit and convert the torque of the crankshaft.
The main characteristic of the gearbox is the gear ratio, i.e. The ratio of the number of teeth of the driven gear to the number of teeth of the drive gear. Gearboxes for KAMAZ are produced with the following gear ratios: 4.98, 5.11, 5.43, 5.55, 5.94, 6.33, 6.53, 6.88, 7.22. The higher the gear ratio (RG), the more the car “pulls”: for example, for mountainous areas it is recommended to use a gearbox with a RF of 7.22, for flat terrain - 5.94, for rough terrain - 6.53. For vehicles without trailers, gearboxes with gear ratios of 6.53, 5.94 and 5.43 are more suitable, but for road trains it is better to purchase vehicles equipped with gearboxes with gear ratios of 7.22, 6.53 and 5.94.
Gearbox device
This is a rather complex mechanism, which consists of the following parts:
Driven cylindrical gear;
- tapered roller bearing;
- semi-axial gear;
- cylindrical roller bearing;
- primary shaft;
- driving bevel gear;
- spacer sleeve;
- bearing cups;
- driven bevel gear;
- main gear housing;
- differential crosspieces;
- satellite;
- driving cylindrical gear.
Methods for determining gearbox faults
In general, the gearbox on a KAMAZ rarely fails, but the enormous loads to which this unit is subjected do not pass without a trace, and therefore breakdowns still occur. Most often, the main symptom of gearbox failure is noise when the car is moving, but extraneous noise occurs when many units break down. The following steps will help you accurately determine that it is the gearbox that is faulty.
- First. As a rule, if the gearbox is faulty, extraneous noise occurs while the car is moving at a speed of about 20 km/h. Gradually increase the speed to 80 km/h, listen and record at what speed the noise appears and disappears. Without pressing the brake pedal, using the engine alone, we reduce the speed to 20 km/h; if noises during braking appear and disappear at the same speeds as during acceleration, then the problem is definitely in the KAMAZ gearbox;
- Second. Accelerate the car to 80 km/h, put the gear in neutral and turn off the engine. If there are no extraneous noises during coasting, but they appear during load, then the gearbox is faulty;
- Third. While parked, start the engine and rev it hard. If there is no noise that was noticed during the first test, then this confirms that the gearbox is faulty.
Typical gearbox malfunctions
Over many years of operation (KAMAZ vehicles have been produced since 1976), experts have identified three main malfunctions that are typical for gearboxes:
Increased heating of the main gear;
- increased noise;
- oil leak.
The reasons for increased heating of the gearbox may be the following:
Excess or lack of oil in the crankcase - it is necessary to drain or add oil to the crankcase;
- increased bearing tension - it should be adjusted;
- incorrect adjustment of gear engagement - also needs to be adjusted.
Increased noise coming from the gearbox on a KAMAZ truck can be caused by the following malfunctions:
Wear of tapered bearings or axial movement in them. It is necessary to check the bearings, adjust them or replace them altogether;
- violation of gear engagement (incorrect side clearance or displacement of the contact patch). This malfunction can be corrected by adjustment;
- wear or damage to wheel teeth. It is necessary to replace the gears (do not forget to then adjust their clearance);
- loosening of bearings. The bearing nuts should be tightened and their preload adjusted.
There are two main reasons for oil leakage from the gearbox: worn cuffs and contaminated breather. In the first case, the cuff must be replaced with a new one, in the second, you can simply clean the breather.
How to measure the level and change the oil in the gearbox housing
To check the oil level, you need to unscrew the inspection hole plug on the crankcase. If the oil does not flow, then you need to add until the oil begins to drip from the control hole.
Changing the oil in the rear axle crankcase is carried out as follows:
Raise the rear truck with a jack and install wheel chocks;
- unscrew the plugs of the control, drain and filler holes;
- drain the used oil;
- screw the drain plug into place;
- fill in 5-6 liters of oil (I-12, IS-21) or diesel fuel;
- start the engine, engage third gear and let the engine run at less than 1000 rpm for about 3-4 minutes;
- turn off the engine, unscrew the plug and drain the flushing fluid;
- tighten the drain plug again;
- fill in fresh oil and tighten all plugs.
Don’t forget to clean the axle breathers: they are washed with diesel fuel and blown with compressed air.
Adjusting the final drive
The repaired crankcase needs to be adjusted after installation on the car. The following mechanisms and values are regulated in the KAMAZ crankcase: preload of the bearings of the driven and driving bevel gears, differential, lateral clearance, as well as the contact patch of the bevel pair.
To adjust the preload in the bevel bearings of the drive gear, proceed as follows:
Reduce the total thickness of the shim pack by the amount of axial movement plus 0.04-0.06 mm. To do this, you can grind or replace one washer;
- with a torque of 240-360 N (24-36 kgf), tighten the nut securing the bevel wheel flange;
- Next, you need to check the rotation force of the bearing cup. It should be 11.4-22.8 N, or 1.14-2.28 kgf. The measurement must be carried out with continuous rotation of the bearing in one direction (at least 5 full revolutions).
If the obtained values differ from the required data, repeat the adjustment.
Adjustment of the preload in the bevel bearings of the driven gear must be done as follows:
Just as in the first case, reduce the total thickness of the adjusting washers by the amount of axial movement plus 0.03-0.05 mm. This can be done either by grinding the washers, or by installing others with the desired size;
- tighten the nut securing the driven bevel gear bearing. The moment should be 350-400 N (35-40 kgf);
- check the rotation force of the bearing cup. It can fluctuate in the range of 14.3-50 N (1.43-5 kgf). This procedure is performed in the same way as when adjusting the tension in the bevel bearings of the drive gear.
If the obtained data is lower or higher than the required values, repeat the adjustment.
After you have adjusted the tension in the bearings of the drive and driven wheels, install them in the gear housing and begin adjusting the side clearance. To do this, you will need shims of various thicknesses. The gap should be 0.20-0.35 mm.
To adjust the differential, it is necessary to install it so that the ring gear of the driven wheel is completely symmetrical to the ring gear of the driving cylindrical wheel. Then tighten the bolts (the torque should be 100-120 N or 10-12 kgf) and proceed directly to the adjustment:
Tighten the adjusting nuts evenly on both sides until the distance between the bearing covers increases by 0.10-0.20 mm;
- tighten the bolts securing the covers with a torque of 250-320 N (25-30 kgf) and lock them.
If you have the slightest suspicion that the gearbox is faulty, then you should not put off repairing it until later. Such delay can be costly in the future.
We hope that this article will be useful to you, and you can purchase the necessary gearbox for KAMAZ in our online store.
To service the gearbox, KAMAZ often uses a special transmission oil of the TAD-17i type. It is chosen by most truck owners - this is due to its low price and good technical specifications. The only drawback is that it thickens in frosty weather.
To avoid this problem, it is better to choose 75W-90 oil for servicing the gearbox - it can work fully both in extreme heat (+35) and in severe frosts (-40). For temperate climate zones, where thermometer readings do not show below -25, 80W-90 lubricant is suitable.
For climatic zones in which the temperature rises to +45 degrees and does not exceed minus 12, use 85W-90 lubricant.
In order for the gearbox to always work properly, it is necessary to use transmission lubricant made only by the world's best companies. Of course, they are much more expensive than similar domestic products, but they improve the suspension mechanism and increase the replacement period.
Optimal oils for KAMAZ
The compositions 75/80W-90 are of high quality, namely:
- Shell Spirax S6 AXME - universal synthesized motor oils.
- Castrol Syntrax Long Life - synthetic for trucks.
- Mobilube HD 80W-90 – equipped with an improved additive package.
Among the transmission ones, Motul Motylgear can be distinguished; among the synthetic ones, Esso Gear Oil GX 80W-90 stands out for its quality. However, when purchasing it, you should be very careful not to become the owner of a fake. Unfortunately, there are a lot of counterfeit products on the market.
How to fill oil into the gearbox?
To perform such an operation, you need to find special holes in the crankcase; there are three of them. They are designed to control the oil level and to fill it. The location of the filler hole is on top of the crankcase, while the control and drain holes are on the axle crankcase.
If the plug is removed from the hole and the oil does not flow, it is necessary to top up until it reaches the required level. The volume of lubricant filled is checked every 8 thousand mileage. If the truck is new, the check is done first after 1000 and then after 4000 km. When the car has passed 50,000 km, it needs to be completely replaced.
What volume of lubricant is poured into the KAMAZ gearbox?
The classic gearbox includes seven liters. To replace, the car is placed on a level surface. In order for the lubricant to completely pour out of the crankcase, it must be heated. Then unscrew the drain plug from below and drain all the existing composition. Diesel fuel is used to flush the gearbox.
The total oil volume is 7 liters, to which is added 750 grams poured into the differential. In KAMAZ 6520, the volume is determined by special marks.
Types of oils for KAMAZ diesel units
The most popular for diesel engines are:
- KAMAZ 15W40;
- API CI-4/SL K10-40.50.
The brand is usually determined by specialists by performing Maintenance cars. In some cases, they use KAMAZ SAE 15W40 API CI-4/SL OPTIMUM KO15-40.50 fluid. The quality of this lubricant is characterized by improved performance.
The operating conditions of the machine also affect the choice of oil brand. Lukoil Super is most often used:
- SAE 15W-40 CE/SG
- SAE 15W-40 CF-4/SG.
To increase engine performance, CES 20078/20076 lubricants are used. Their properties of these oils protect the engine from increased wear and reduce friction.
The latest engines installed on KAMAZ must meet modern environmental requirements. To increase the reliability and durability of the engine, the following oil is poured into the most modern KAMAZ trucks:
- Lubri-Loy15w40 API CJ-4/SN;
- CES 20081;
- Lubri-Loy API CI-4/SL Multi-Grade;
- CES 20072.
Each truck driver himself chooses the appropriate brand of oil for his KAMAZ. However, it is imperative to adhere to the car manufacturer's recommendations. Only in this case will the machine work for a long period without major repairs.
Recommended reading: admin 09/27/2017To the question “What kind of oil should I pour into the KamAZ gearbox?” The answer can be simple - the choice of oil depends on the preferences of the car mechanic or driver and his wallet size.
Gear oil 75W-90 or 80w-90 from any well-known manufacturer is the most optimal choice. The main thing is not to run into a fake!! The issue is price, imported oils are expensive, but we recommend:
1) Castrol Syntrax Long Life 75W-90 - fully synthetic universal gear oils trucks. Especially recommended for heavy final drives commercial vehicles. Has excellent performance properties and an extended replacement interval.
2) Shell Spirax S6 AXME 75W-90 - unique synthetic fuel-efficient drive axle and gearbox oils with long service life - maximum protection for the most modern, heavily loaded axles. It has special anti-friction characteristics and high fluidity, which reduces power loss, lowers operating temperature and increases mechanical efficiency.
3) MOTUL Motylgear 75W-90 - Transmission oils for heavily loaded gearboxes and hypoid axles without automatic locking and limited slip systems. Standards: API GL4 and GL5; MIL-L-2105D.
4) Mobilube HD 80W-90 - high-performance oils for heavily loaded gears, produced from high-quality base oils and an improved additive package. This oil is designed for automotive applications, including highly loaded axles and final drives (gearboxes), where high pressures and shock loads are encountered. It provides superior performance where API GL-5 performance levels are required.
5) Transmission oil TAD-17i (analogous to TM-5-18) - universal all-season mineral oils for transmissions of trucks, as well as other mobile equipment operating in difficult temperature conditions at high specific loads and sliding speeds. It has a highly effective additive package (multifunctional sulfur-phosphorus additive, depressant and anti-foam additives). TAD-17i oil (analogous to TM-5-18) is ideal for lubricating all types of gears, including hypoid ones. The oil composition includes, in addition to residual oils, distillate oils obtained by fractional distillation of fuel oil. It has a particularly strong oil film, ensuring reliable operation of the transmission under intense friction conditions in the contact areas. TAD-17i (TM-5-18) oil is operational in the temperature range from -25°C to 130-140°C, degrees.
6) Esso Gear Oil GX 75W-90 is a partially synthetic all-season transmission oil for use in heavily loaded modern final drives (reducers), especially for hypoid final drives and special speed gearboxes.
Many KAMAZ drivers fill in TAD-17 transmission oil, because... it is cheaper and quite usable. The only thing is that in the cold season at a temperature of -30..-35 degrees the oil thickens a lot, because... oil 80W-90.
| Ranges of application of transmission oils | ||
| Minimum temperature for ensuring lubrication of components, °C | SAE class | Maximum temperature environment, °С |
| -40 | 75W-80 | 35 |
| -40 | 75W-90 | 35 |
| -26 | 80W-85 | 35 |
| -26 | 80W-90 | 35 |
| -12 | 85W-90 | 45 |
We recommend using gear oil famous brands Shell, Esso, Mobilube, Mobil, Motul, Castrol with class according to SAE 75W-90 (application range -40...+35С) or 80W-90 (application range -25...+35С). If the average temperature in the area where you operate your car is -15C, then transmission oil TAD-17i (analogous to TM-5-18), operating in the temperature range from -25°C to +35°C, is quite suitable.
7.75 liters of transmission oil are poured into the gearbox of the KamAZ 5320-2502010-10 middle axle. It is advisable to fill through the MOD (center differential). 0.75 liters is poured into the MOD.
7 liters of transmission oil are poured into the rear axle gearbox of KamAZ 5320-2402010-10.
Check the oil level and quality regularly. Insufficient oil level in the axle housing leads to a continuous howling noise when the truck is moving.
Do you want to buy a KamAZ gearbox? Call us with your request, our managers will advise you on cost, shipment to your city, payment options.
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