The Ural 4320 is a popular truck that is excellent for use on rough terrain and in forestry. This is facilitated by high ground clearance and a powerful engine. This machine is equipped with YaMZ diesel engines. Power can exceed 300 horsepower. The gear shift scheme is competently designed by the manufacturer of this equipment. Approximately 30 liters of fuel are consumed per 100 km. If this indicator has increased, it is necessary to carry out premature diagnostics of the automotive system.
The winch for the Ural-4320 is necessary for self-pulling vehicles or pulling out other vehicles. Maintenance of the winch consists of directly checking and tightening all fasteners.
How does the checkpoint work?
The KPP-141 device, installed on some Ural models, includes the following elements:
- Coupling mechanism. It helps temporarily separate the engine and transmission. This allows you to change gears without reducing the speed of the power unit.
- Driven gears and shafts. The drive, intermediate and secondary shafts are installed here.
- Synchronizer. It ensures silent operation of the mechanism and equalization of gear speeds.
The gears rotate freely when the neutral mode is engaged, at which time all clutches and synchronizers are in the open position. When the driver begins to squeeze the clutch mechanism and shifts the handle to some other gear, a special fork device begins to move the clutch into the engagement position with the corresponding pair at the end of the gear.
The gear mechanism is rigidly fixed to the shaft and stops spinning on it. The clutch in this position facilitates the transmission of rotational motion and traction force.
While the vehicle is moving, the gearbox is activated by the gear shift knob. It moves sliders equipped with forks, which begin to move the synchronizers at the required speed. A color diagram of gear shifting is in the Ural user manual.
Gear ratios of the Ural box:
- first stage - 5.26;
- second stage - 2.90;
- third stage - 1.52;
- fourth stage - 1.00;
- fifth stage - 0.664;
- reverse gear - 5.48.
Transmission system components
Ural vehicles are valued for their high power characteristics, excellent load capacity, and driving dynamics. The performance indicators of this vehicle are largely influenced by the installed gearbox. This device affects power gain.
The Ural-4320 is equipped with a five-speed gearbox. It has a long service life and can withstand the loads placed on it well. The Ural gearbox housing is attached to the clutch housing. The manual transmission on the Ural car has fixed shaft axles. The upper crankcase cover is equipped with a gear shift mechanism.
Gearbox diagram
The transmission system includes lockable cross-wheel and center differentials. On the truck there is a dependent power take-off box or KZOM.
It should be noted that there is a transfer case on the Ural 4320. It is 2-stage and affects the fuel consumption for each kilometer traveled. This box is securely fixed to the frame with several special rubber pads.
Power take-off box
The Ural transfer box is an additional gearbox. It ensures stable movement of the machine at low speed. The installed Ural power take-off is single-stage. It is necessary to drive auxiliary units.
Gearbox Power Line Gear Shift Mechanism
Malfunctions and repairs
Basic malfunctions and repairs of the box:
- Extraneous noise in the mechanism. In this case, it is recommended to conduct an external inspection of the system and replace damaged and worn parts.
- The shafts move along the axis. It is necessary to replace the parts that secure the bearing, or replace failed bearings.
- Unstable operation of the gearbox. This problem may be due to wear on the reverse spline shaft bushings. Damaged mechanisms should be replaced.
- The clutch does not engage fully. In this case, it is recommended to conduct an external inspection of the coupling mechanism for damage and defects, check the level of lubricating fluid in the system and replace damaged elements.
- The fork rods are difficult to move. This malfunction can be caused by damage to the locking pins and synchronizers. It is necessary to replace the mechanisms with new ones.
- If the gearbox switches off spontaneously, it is necessary to adjust the gap between the valves, replace worn synchronizer rings, install new springs, and tighten fasteners.
- If the switching is unclear, you need to remove the cover of the locking device and inspect the main components for wear, replace the clutch and gears.
Gearbox repairs are carried out only with the power unit turned off.
How to adjust
The gearbox is adjusted as follows:
- The vehicle is installed on a special platform.
- Using a jack, slightly raise the front part of the car body and fix it in this position.
- On the transmission control rod, loosen the fastening nuts of the clamp bolt. The nut is loosened 4.5 turns.
- Using a screwdriver, expand the grooves at the end of the traction device and the clamp.
- Move the rod to the neutral position.
- Unscrew the special fasteners.
- Remove the gearbox cover from the control handle. The cover is lowered to the very bottom of the case, and the handle itself is placed in a vertical position with the end up.
- Loosen the clamp mechanism.
- Engage reverse gear when the power unit is not working.
- Install the prepared template into the trim window, as well as the reverse locking bracket.
- The stop of the axial mechanism is inserted into the groove of the template and pressed against the system body.
- Set the required gap between the elements. Tighten the fasteners and clamp.
- Start the engine and check the serviceability of the adjusted gearbox.
How much oil to fill
Oil must be added in accordance with the user instructions. For Ural cars, the sufficient oil fluid level is 3.5-4 liters.
TRUCKS GAZ, ZIL, KAMAZ, URAL, MAZ, KRAZ
_________________________________________________________________________________________
Gearbox Ural-4320
Until 1994, Kamaz-141 gearboxes (for the Kamaz-740 engine) were installed on Ural-4320 and 5557 vehicles. Since 1994, Ural-4320 vehicles and their modifications have been equipped with YaMZ-236 engines with a YaMZ-236 gearbox or with a YaMZ-2361 gearbox (a modernized version of the YaMZ-236 gearbox). Gearbox Ural-4320, 5557 (YaMZ-236) Gearbox YaMZ-236 for Ural-4320, 5557 vehicles - mechanical, three-way, five-speed (five gears for forward movement and one for reverse) with synchronizers for 2–3 and 4–5 transmissions Modification of the gearbox - YaMZ-236U. Gear ratios of the gearbox Ural-4320, 5557 YaMZ-236 U Transmission Gear ratios 1 5.26 2 2.90 3 1.52 4 1.00 5 0.664 Reverse 5.48
Rice. 13. Gearbox of Ural-4320, 5557 (YaMZ-236) vehicles 1– clutch release clutch; 2–primary shaft; 3, 15 – bearing caps; 4–clutch housing; 5, 10 – synchronizers; 7 – retainer ball; 8, 22–fifth gear gears; 9, 21–third gear gears; 11, 19 – second gear gears; 12–first gear and reverse gear; 13–top cover; 14–secondary shaft; 16–flange; 17 – intermediate shaft with first gear gear; 18–gearbox housing; 20–oil pump intake with magnet; 23– power take-off gear; 24–intermediate shaft drive gear; 25–oil pump; 26–axis of the reverse gear block; 27–reverse gear block; 28–speedometer drive gear. Primary shaft 2 (Fig. 13) of the Ural-4320, 5557 gearbox is mounted on two ball bearings. The front bearing is pressed into the engine crankshaft bore. During assembly, the bearing cavity is filled with Litol-24 lubricant and sealed with a cuff. The rear bearing is secured against axial movements in the front wall of the gearbox housing and the bearing cover using a retaining ring. The front end of the secondary shaft 14 rests on a roller bearing placed in the socket of the primary shaft. The rear end of the secondary shaft of the Ural-4320, 5557 gearbox rests on a ball bearing secured by a retaining ring in the crankcase wall and cover. A flange 16 is installed on the splines of the rear end of the secondary shaft for fastening the propeller shaft of the vehicle. The intermediate shaft 17 is mounted on two roller bearings. The front end of the intermediate shaft of the Ural-4320, 5557 gearbox has a groove for driving the oil pump. The reverse gear block 27 rotates on two roller bearings mounted on a fixed axis 26. All gears of the Ural-4320, 5557 gearbox have spiral teeth, except for the spur gears of the first gear, the reverse gear and the power take-off gear. The second, third and fifth gears and a pair of intermediate shaft drive gears are in constant mesh. The gears of the second, third and fifth gears of the secondary shaft are mounted on steel plain bearings with a special configuration, coating and impregnation. Shockless engagement of the second, third, fourth and fifth gears is ensured by two synchronizers 6 and 10. The Ural-4320, 5557 inertial type gearbox synchronizer allows the gear coupling of the carriage to engage with the gear coupling of the gear only when the angular velocities of rotation of the gear and shaft are equalized. The speed equation is carried out using a friction pair - a synchronizer cone ring and a cone on the gear. Engaging first gear and reverse gear is carried out by moving gear 12 along the splines of the secondary shaft until it fully engages with the corresponding gear. The top cover of the Ural-4320, 5557 box contains a three-way gear shift mechanism. On the rods of the Ural-4320, 5557 gear shift mechanism, forks are attached, which, when the rods move, move the synchronizer carriages or the first gear and reverse gear. The rods are held in the desired position by ball retainers 7. To protect against accidental engagement of two gears at the same time, the Ural-4320, 5557 gearbox has a locking device (type A–A), consisting of a pin and two pairs of balls; when any rod moves, the other two are locked balls that fit into the corresponding grooves on the rods. To protect against erroneous engagement of reverse gear and first gear, spring fuse 32 is used. To engage reverse gear or first gear, the additional force of the fuse spring must be overcome. Through gear 23 (Fig. 13), power can be taken to drive additional units. The power take-off mechanism is attached to one of the flanges with hatches located on both sides of the gearbox housing. The Ural-4320, 5557 gearbox is equipped with a speedometer drive mechanism located in the cover 15 of the rear bearing of the secondary shaft (view B-B).
Rice. 14. Diagram of the lubrication system of the Ural-4320, Ural-5557 gearbox A – oil suction; B—high blood pressure; 2–oil intake magnet; 3–oil intake mesh; 4–drain plug; 5– oil pump; 6–reducing valve; 7–filler plug The lubrication system of the Ural-4320, 5557 gearbox is mixed (Fig. 14). The sliding bearings of the secondary shaft gears are lubricated under pressure. Rolling bearings, gears and the gear shift mechanism of the Ural-4320 are splash lubricated. Oil is sucked from the crankcase oil bath through the intake and channel system by gear oil pump 5, installed on the front wall of the gearbox housing and driven from the intermediate shaft. The oil intake is closed with a mesh 3 and has a permanent magnet 2 to catch small metal particles in the oil. The oil pump is equipped with a pressure reducing valve 6, adjusted to a pressure of 80±10 kPa (0.8±0.1 kgf/cm2). Oil is poured into the Ural-4320 gearbox through a hole in the top cover, closed with a plug, to the level of the control hole located on the left side of the crankcase. The filling capacity of the Ural-4320 gearbox lubrication system is 5.5 l. The internal cavity of the Ural-4320, 5557 gearbox housing communicates with the atmosphere using a breather. During maintenance, check the fastening of the Ural-4320 gearbox to the engine and the condition of its suspension, maintain a normal oil level in the box and promptly replace it according to the lubrication table.
Rice. 15. Transmission plugs Ural-4320, 5557 (YaMZ-236) 1 – oil filler hole; 2–oil pump intake cover; 3–oil level inspection hole; 4–drain hole The oil level in the gearbox housing must not be lower than the lower edge of inspection hole 3 (Fig. 15). Drain the oil from the Ural-4320, 5557 gearbox housing while hot through the drain hole closed with plug 4. After draining the oil, clean the magnet of the drain plug. After draining the oil, unscrew the bolts and remove cover 2 of the oil pump intake, clean and rinse the mesh, and then replace the cover. When installing the intake cover, be careful not to block the oil line with the cover or its gasket. It is recommended to wash the Ural-4320, 5557 gearbox with industrial oil I-12A or I-20A in accordance with GOST 20199 - 88; 2.5 - 3 liters - pour it into the gearbox crankcase, set the gear shift lever to the neutral position, start the engine for 7...8 minutes, then stop it, drain the flushing oil and fill with fresh oil. It is strictly forbidden to flush the Ural-4320, 5557 gearbox with kerosene or diesel fuel in order to avoid failure of the oil pump due to insufficient suction vacuum and, as a result, failure of the gearbox. In case of complete overhaul of the Ural-4320 gearbox, lubricate the oil pump with the oil used in the gearbox before installation. When towing a car with the engine not running, the input and intermediate shafts of the Ural-4320, 5557 gearbox do not rotate, the oil pump in this case does not work and does not supply lubricant to the bearings of the secondary shaft gears and to the cone surfaces of the synchronizers, which will cause scuffing of the sliding surfaces and wear of the rings synchronizers and leads to failure of the entire gearbox. To tow, disengage the clutch and engage direct (fourth) gear in the gearbox or disconnect the gearbox from the transmission. Towing a vehicle over a distance of more than 20 km without disconnecting the driveshaft or squeezing the clutch with the direct transmission engaged is not allowed. To prevent premature wear of the rubbing pairs, it is recommended to warm up the gearbox before starting the engine at an ambient temperature below -30°C. If this is not possible, then drain the oil from the crankcase while the engine is stopped for a long time, and before starting the engine, heat this oil and pour it into the Ural-4320 box through the hole in the top cover. For smooth and easy gear shifting and protection of the teeth of the intermediate shaft and six gears of first gear and reverse gear from end wear, as well as protection of rings. synchronizers from wear, properly adjust the clutch and prevent it from “driving.” Gearboxes Ural-4320, Ural-5557 (YaMZ-2361) The YaMZ-2361 gearboxes are a modernized modification of the YaMZ-236 family of gearboxes. On the Ural-4320, 5557 gearboxes of the YaMZ-2361 type, a reinforced input shaft was introduced by increasing the shaft diameter, the input shaft seal and the lubricant supply system from the oil pump to the input shaft cover were changed. The lubricant is supplied through an oil pipeline from the oil pump to the input shaft cover. Gearbox model YaMZ-236U - after change - YaMZ-2361-50 The Ural-4320, 5557 gearbox assembly complete with a diaphragm-type clutch is interchangeable when replacing the driven clutch disk 182.1601130 with 182.1601130-10 with an increased inner diameter of the hub and clutch release clutch 183.1601180 -01 to 184.1601180-31. The name and designation of parts of the Ural-4320, 5557 gearboxes complete with a diaphragm-type clutch before and after changing the gearbox are given in the table. Name of the part, gearbox unit. Part designation (Before change), Quantity / Part designation (After change), Quantity Primary shaft with tube assembly 236Н-1701027-Б 1 / 2381.1701025* 1 Primary shaft cover 236-1701040-А 1 / 2381.1701040 1 Oil pump 236-1704010 -A 1 / 336.1704010-10 1 Gasket 236-1704017-A2 1 / - - O-ring - - / 336.1704019 1 Pipeline - - / 336.1704300 1 Cuff 236-1701230 - / 201.1701230 1 Bolt M1 6x1.5-6 — — / 310264- P29 2 Gasket — — / 201.1015624 4 Thrust ring — — / 201.1721413 3 Note: * — Primary shaft with rear bearing and tube assembly. For the conversion of Ural-4320, 5557 gearboxes of the YaMZ-236 type into gearboxes, respectively, of the YaMZ-2361 type, a set of spare parts 2361.1700200 was created, including the parts and assemblies necessary for replacement.
_________________________________________________________________________________________
- GAZ-3307 clutch maintenance
- Steering system GAZ-3307
- Gearbox parts for GAZ-3307
- Maintenance of the rear axle GAZ-3307
- Maintenance of the fuel system of the D-245 diesel engine
- Clutch GAZ-3309 with a diesel engine
- Operations for disassembling the GAZ-3309 gearbox
- GAZ-3309 front axle service
- Repair of cardan shafts of GAZ-3309 cars
_________________________________________________________________________________________
_________________________________________________________________________________________
- Operations for assembling basic components of the ZIL-130 engine
- Service and repair operations for the ZIL-130 gearbox
- Maintenance and repair of ZIL-130 clutch
- Repair and adjustment of the rear axle ZIL-130
_________________________________________________________________________________________
- KAMAZ-4310, 43118, 43114
- KAMAZ-5320, 55111, 53212, 5511, 55102
- KAMAZ-65115, 6520, 65117
- KAMAZ-4308
- Engine KAMAZ-740
_________________________________________________________________________________________
- Parts of the cylinder block and head of the YaMZ-236 engine
- Service maintenance of the YaMZ-236 piston group and crankshaft
- Diagnostics and technical adjustments of the YaMZ-236 engine
- Design and adjustment of fuel injection pump and injectors of the YaMZ-236 engine
- Cylinder block and piston YaMZ-238
- Components of the YaMZ-238 diesel fuel supply system
- Design and adjustment of the fuel injection pump of the YaMZ-238 diesel engine
- Technical design of the YaMZ-239 gearbox
_________________________________________________________________________________________
- Components of the front axle and steering rods of the Maz-5516, 5440
- Steering system of Maz-5516, 5440 cars
- Clutch and gearbox parts Maz-5516, 5440
- Maintenance of drive axles of MAZ-5516, 5440 vehicles
- Power steering for Maz-5551, 5335 cars
- Maintenance of cardan transmission of Maz-5551, 5335 cars
- Maintenance and adjustment of clutch MAZ-5551, 5335
- Repair and service of the rear axle of MAZ-5551, 5335 cars
_________________________________________________________________________________________
- Gearbox Ural-4320
- Construction and adjustment of Ural-4320 bridges
- Maintenance of transfer case Ural-4320
- Steering components Ural-4320
_________________________________________________________________________________________
- Servicing the KRAZ-255, 260 gearbox
- Steering mechanism and power steering Kraz-255, 260
- Adjustments and repairs of the power steering cylinder and steering rods of the Kraz car
- Drive axle components and drive shafts Kraz-255, 260
How to remove and disassemble
In order to dismantle and disassemble the gearbox, you must:
- Place the vehicle on a lifting device or inspection pit.
- Remove the batteries, air filter element and mudguards. They are located at the bottom of the engine compartment, in the center and along the edges.
- Remove the front suspension cross member and the front drive wheel drives.
- Drain the transmission fluid from the box.
- Disconnect the wires of the sensor responsible for speed indicators. To do this, you need to pry up the wires with a screwdriver and carefully remove the spring retaining device.
- Remove the vehicle reverse switch.
- Remove the engine harness holder.
- Remove the mounting bolts from the gearbox and the hydraulic clutch release bracket.
- Remove the bolts from the working cylindrical block, clutch housing, amplifier.
- Remove the crankcase.
- Place a support under the dismantled box.
- Disconnect the front and rear supports from the bracket.
- Move the gearbox back and place it on a hard surface.
- Unscrew the fasteners and disassemble.
Engine
Engine type – four-stroke two-cylinder. Brand – M-72M. Cylinder diameter, mm – 78. Piston stroke, mm – 78. Working volume, cm³ – 746. Compression ratio – 5.5 ± 0.2. Maximum power, l. With. – 22. Maximum torque, kg m – 4.0. The block head material is aluminum alloy. Head gasket – asbestos metal 0.6 mm. The piston material is aluminum alloy.
Valve distribution phases (according to the angle of rotation of the crank), degrees: – beginning of intake to c. m.t. – 76; – end of inlet after n. m.t. – 92; – beginning of release BC m.t. – 116; – end of release after c. m.t. – 52.
Carburetor – Two K-37.
How to assemble and install
Box assembly procedure:
- compress the bearing;
- insert a chisel into the gap between the end part of the inner bearing ring and the differential box;
- install the bearing and axial mechanism of the satellites;
- insert the support ring into place;
- install drive gears and differential box;
- tighten the fasteners;
- install the synchronizer blocking ring;
- install the sliding clutch and retaining ring of the synchronizing device hub;
- install the driven gear and thrust washer;
- adjust the gap between the front bearing ring and the drive gear.
Ural motorcycle gearbox with reverse speed
How to independently remove, disassemble and assemble the gearbox of a Ural motorcycle.
Over its long life, the gearbox of the Ural motorcycle has undergone several modifications, including the addition of a reverse gear. The use of a secondary shaft in the gearbox made it possible to increase productivity and significantly reduce the size of the box, which is very important for a motorcycle. Repairing and assembling the gearbox of a Ural motorcycle is not very difficult, and this work can be done independently.
How does a Ural motorcycle gearbox work with reverse gear?
The two-shaft gearbox of the Ural motorcycle uses fewer gears when transmitting torque, which is the main reason for the increased efficiency. The input shaft of the gearbox has three initial speed gears, which are integral with the shaft. The purpose of the secondary shaft is to select the required gear, and the gears on it are not rigidly fixed. The gearbox of the Ural motorcycle with reverse speed has manual and foot shift methods, which makes it very convenient to use.
On later modifications of the gearbox, a removable rear cover appeared in the aluminum crankcase, allowing the gearbox to be repaired without removing it from the engine.
Among other motorcycles, it is precisely the ease of maintenance that distinguishes the Ural motorcycle - a major overhaul of the gearbox can be easily completed within a day, if the appropriate spare parts are available. It must be remembered that some parts from various modifications of the gearbox are interchangeable. This is one of the main advantages that makes it quite easy to assemble a working box from several faulty ones.
When to shift gears on a manual transmission: gear shift order and features
Passenger cars are usually equipped with a 4-speed, 5-speed or 6-speed gearbox. On trucks, the number of gearbox gears reaches 12 (due to the use of half stages for more efficient use of internal combustion engine torque under high traction loads).
At the same time, it is the manual transmission that allows you to fully understand the concept of “driving a car.” In order to learn how to drive a manual transmission and professionally drive a car with such a gearbox, you need to understand the circuit diagram of its structure and know the operating principle of its mechanisms.
Removal and repair of Ural motorcycle gearbox
To remove the gearbox without unscrewing the motor, you need to do the following:
- Remove the rear wheel from the motorcycle.
- Remove the cardan drive.
- Remove 1 bolt and 3 nuts securing the gearbox to the engine.
- Then the gearbox can be pulled out of the motorcycle frame and you can begin to inspect it.
Repairing a Ural motorcycle gearbox involves replacing worn gears, followed by adjusting the gear shift mechanism. You should also pay attention to the seals - their wear will cause oil leakage, as a result of which the Ural motorcycle gearbox will operate in conditions of insufficient lubrication.
Dismantling and assembling the gearbox of a Ural motorcycle
To disassemble the gearbox, proceed as follows:
- dismantle the clutch mechanism along with the bearing;
- remove the starter lever, then the rubber coupling located on the secondary shaft;
- remove the gear shift housing cover;
- Unscrew the lid of the box and carefully remove it from the shafts.
Complete disassembly of the clutch mechanism, gear selection mechanism and kickstarter is allowed only when repairing them - otherwise there is no need to disassemble them.
The Ural motorcycle gearbox is assembled with reverse gear in reverse order. After assembly, the gear shift mechanism must be adjusted, otherwise problems may arise when choosing them.
The gearbox of a Ural motorcycle with reverse speed begins to be adjusted by placing the motorcycle on the stand. Then the 2nd speed is turned on and the pedal is pressed to the 3rd gear. If the ball coincides with the well, adjustment of the lower adjustment screw is not required. After moving from 3rd speed, you need to return to the second and check the alignment of the ball, tighten the upper screw if it does not match. This completes the gear selection adjustment.
The Ural motorcycle allows you to repair the gearbox with minimal effort, thanks to the simplicity of its design, which distinguishes this model from other two-wheeled vehicles.
Valve adjustment for Ural M-67, IMZ
On this engine the recommended clearance is 0.05mm.
Therefore, you will need a probe with exactly this thickness. It also has slightly different saddles, but this does not affect the adjustment process. The motorcycle should also be tilted before starting work. The process occurs as follows: This is how you can easily and quickly adjust the valves. This work is not difficult, but it will avoid many problems with the engine. Also, with properly adjusted valves, flow is reduced.
Source
