Factory restoration of automatic boxes: how it is done and how much costs. What do you need a friction clutch

Welding boxes Transmissions "Argon", whether the manual transmission or automatic transmission, most affordable and most acceptable, and often perhaps the only option that allows the car owner at the same time to save not only the "family budget", but also more expensive - "time" spent on repairs. One of the essential aspects affecting the choice in favor of welding is the total price of plumbing and welding, because welding makes it possible to eliminate the "defect" itself, even without dismantling the gearbox from the car.

Of course, we are from the part "slightly" exaggerate the process of preparing and welding a damaged "unit", factors affecting the need to remove the "box" from the car abound. The main of which, "character", the degree of damage and the possibility of conducting welding work directly "by car". Of course it is worth considering and "material" from which the housing (crankcase) of your gearbox is made. The most renovative is the box of aluminum alloys, which include a variety of silhouettes, Magnals and partially duralumin.

Find trouble on your "gearbox", even without leaving such a megalopolis as Moscow is quite simple, and country trips in a hundred times increase the likelihood that you will have to seek the "Welding PPP or ACP" service in the foreseeable future. As a rule, the lion's share of defects (which are subsequently corrected by "welding) relate to mechanical damage. A crack on the checkpoint in 99% of cases is a consequence of the effects of excessive load on the crankcase body, and the reasons may be different.

Banal inattention of a car owner, this is the dominant reason forcing "customers" to come to us to the technical center (located in CJSC, Yuzao Moscow), after the "meeting" boxes with a border, reinforcement, a pit and other construction or natural obstacle, no less rare cases of damage to the box when Accident (in which the protection of the engine crankcase and the gearbox is powerless). Errors of car owners - amateurants, with self-replacement clutches lead to the fact that incorrect installation Boxes of the car on the car, they manage to break the "ear" on the checkpoint, and at best, only the fastener that appears near the transmission mounting hole is found.

Welding CPP Box - Argon

First of all, profile specialists determine the expediency of applying "argon welding", many damage even perfectly "treated" by two-component glue, subject to compliance required conditions and guaranteed results. To some defects on " mechanical box"refer to condescendingly, because the insignificant flow transmission Oil They are not as dangerous on them, like on the boxes of machine guns ...

Most problematic, defects are considered not allowing the machine daily to operate, they include:

Gallery - Welding Boxes "

• "Hole" in the gearbox - through hole in the housing that does not allow stably maintaining necessary level transmission oil (ATF oil);
• The gearbox burst, the danger of the crack appeared is that her education (with the exception of the strike) "says" about the malfunction of the gearbox itself (so the destruction of one of the bearing of the secondary shaft, often leads to the appearance of a crack on the housing of the clutch side), and "Voltage" in the metal can lead to further cracking. Argon welding without repair of the checkpoint in such cases is ineffective;
• Slap a piece from the gearbox, only with the help of welding, you can put together a plurality of breakaway fragments that form crankcase boxes;
• Blooming the KPP, one of the most common defects, sometimes not allowing to fix the installed gearbox on one of the numerous "pillows" - fastening supports, as a rule, requiring the surfacing of the missing fragment (with cutting or without a "cutting" threaded connection).

Welding Boxes - Technology

One of the advantages of our services is mobility, because it is much easier to "brew a box" in the car service in which you turned, rather than shoot and carry it to us. We ask our customers, with understanding, please send a photo of a defective area to "Viber" (Viber) or "WhatsApp" (Vatsap), in turn, this will allow us to quickly orient you on time and price of our service "Welder for departure.

Some restrictions when using welding equipment are affordable to the damaged area and the possibility of restoration work without resorting to the dismantling of the CAT. Worth considering preparatory workSupposed in the preparation of the surface of the welded part, which is properly cleaned and degreased ...

Welding is performed by welding equipment to welded aluminum-based alloys, they include silumin, malty and duralumin. After all, for the most part, the gearbox housing is made of these alloys. The strength of the current and the additive rods are selected individually for each box.

The task of the welder - argoner, eliminate the defect ensuring the tightness and strength of the weld, without creating the deformation of the product. Alas, the welding process itself is not so simple, the nuances right choice Tungsten electrode, an ampera of welding current, welding polarity, argon feeding to the arc formation zone, selection of the brand of a twisted bar and professional "chameleon is only 10% success.

The remaining 90% of success, depend on the integrity of our welders, heat the edges of the welded parts, but not to allow the metal overheating only a profile welder, because overheating can lead not only to the formation of the cracking of the weld, but also to the "boost" of the aluminum alloy and as a result of the appearance "bubbles" in the weld, and the porous seam structure relaxes it ...

I have not a remarkable structure on the site with cars, the door, the staircase, the dark corridor, the basement, again the door ... The first thing you get into the "purgatory" - a small room of the type of the gateway chamber that divides this world, with the racks of the chumased and the "dead" automatic transmission, And the one is mysterious and sterile.

Immediately make a reservation that any attempts of car enthusiasts to reach ZF are not directly successful. The concern works only with official dealer centers and car services that provide automatic transmission for industrial recovery.

What does it differ from repair? The fact that not only the worn or broken part is changing, but all others whose parameters differ from new ones. Sometimes the old remains only the case and some details with a large resource of work.

Warranty cases On the automatic transmission zf we did not have. All that came to us either developed their resource, which happens infrequently (on the stand tests it is about a million kilometers, to become engines, in russian conditions Operation, about 250-500 thousand), or failed due to the wine owner

Oleg Molotkov

Time went

To get into the world of micron tolerances, a faulty gearbox, or "Cor", as they are called here, there are several stages. In its first, it is washed with an alkaline solution in a special, resembling an airhril device.

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Then with the help of special hoists move to a sandblasting chamber. It is with inner gloves - similar design is used to work with radioactive elements. Only sand in the chamber is not a quartz, but plastic. The hands of the mechanic who received the order-outfit for the restoration of the unit and 7 hours of time for the entire process, move over the screw nozzle nozzle of the feed hose with sand-air mixture. A couple of minutes, and the case looks like a new one. Another washing, and the "patient" on a special trolley ship on the "parsing" and resuscitation activities.

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There are five ZF industrial recovery centers in Russia, one of which in Russia. And he works on all countries of the Customs Union, and sometimes on far abroad. In the center there is not a single mechanic who ever engaged in the repair of gearboxes in Russia. All of them were recruited without experience, with ordinary technical education and trained in Germany. It is believed to move our "specialists" - very expensive.

All errors, including overheating and busting, time and conditions of their occurrence, are recorded in the mechanical control unit of the ACP. But it is impossible to "read" this data, neither Chinese multimarocre scanners, nor every WAG-comami - only a dealer or factory scanner. The latter is distinguished by advanced functionality.

If you simply deleted an error using a dealer scanner, it immediately finds out after viewing backup. It is also immediately visible, "native" whether it stands for mechatronics. It is determined by the mileage of the box, and, depending on this, these or other details are changing.

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After a few minutes, graphics and tables appear on the monitor. The diagnosis is manually entered into a defective sheet, and the box is sent to the disassembly. By the way, one of the most important parameters is the automatic transmission number. Only on it can be defined all source parameters.

The aggregate under study passed only 53 thousand km, but he was not lucky. In the friction package D fell fluid pressure, the electronics tried to straighten the situation, but unsuccessfully. The process of adaptation passed incorrectly, as they say and numbers, and built graphics. They are a guide to action for the mechanic. When disassembly, the P package will be examined with special addiction.

So, the electron-detectable box is dismantled, part of the parts on the table, part on a special rack, reminiscent of a dishwasher basket. All friction closures are built in order, as a plate of a large table service.

The first task of the mechanic is to test the wear of the shafts and the sleeves on the input shaft and the gaps in the packages, on the basis of which, if necessary, adjustment rings are prescribed. Table of tolerances on the wall - mystery for seven seals, which is its own for each execution of automatic transmission. On the lymba micrometer in the hands of the master of 1.92. Alas, will not go.

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And here is the "bagel", that is, a hydrodynamic transformer, or abbreviated GDT. The modern "bagel" is a hybrid of hydraulic and conventional, friction clutch. Let's not go into the details of the design - in detail. The friction pad has the property to wear out and pollute the oil with its remnants.

And repair, according to ZF technologies, "Bublik" is generally not subject. The sawing of it, replacing the locking lining and welding back to the subsequent balancing - is it even a working, but handicap type of repair. According to the rules, it is necessary to change assembly.

However, if the lining is still "alive", the GDT can be washed on the machine. But if, say, the friction gear frictions have the fifth, the last degree of wear with the destruction of the metal, it will no longer help. Chip from the hydrotransformer do not wash. In the meantime, the "bagel" is hermetically fixed between the clips, through which pure oil is supplied under pressure, and it turns out to be perfectly clean soon.

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While "washing" GDT, the mechanic stones the part catalog, choosing the necessary for the replacement, according to the defect sheet, and goes to the warehouse, where it expects a collected package of spare parts. Exceptionally original, of course.

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Installing them correctly and with the necessary gaps will not work without the ZF instruction scheme and a special tool: a variety of mandrels, keys and other glands, which will not pick up the names from the first time.

It seems, everything, the automatic transmission is collected and can be considered restored, but it is only an unprofessional look. The next Tal suffers it to a table next to the water filled with water, only without fish. Swimming for tightness is another test. Through the housing inserted into the technological hole, the fitting is filled with compressed air, and the "automatic" slowly overtures under water. If there are no bubbles on the surface - the drying and the next test, if appeared - again on disassembly.

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But this practically does not happen, with the exception of history, when the leakage of the body could not find a leakage of liquid from the body. The defective gland was discovered just in this aquarium.

The same process takes place in factory testing and new ACP. Transmission after recovery should have all the characteristics and resources, as well as just released from the factory. Jaguar requirements Land Rover. Or BMW, in which ZF transmissions are used, very high, because our task is fully consistent.

Oleg Molotkov

leader: general director of LLC "CF Russia"

Further, the ACP is sent to new tests on the stand that imitates the operation of the engine. The box control unit over the Internet is connected to the remote ZF server, and in it, on the basis of a read number, the most relevant test for the test is poured. Then the stand simulates all possible modes of the engine with which the "automatic" must perfectly cope.

Intervene in the process, the mechanic can not, as well as set its parameters. But if suddenly hear outsiders, the inconspicuous aggregate is obliged to stop the test and send a node to alteration. The result of an impartial examination is printed and applied to the restored unit.

The latest stage is the firmware of mechatronics with "binding" ACP specific engine. However, "registration" can be done on dealerships.

How not to get?

Do not have the chance at all how to restore the automatic transmission, and travel for a long time and happily? First, it is worth watching the car as a whole. First of all, behind the cooling system, because the automatic transmission does not tolerate overheating.

Secondly, the box needs to change the oil. Minimum - every 60,000 kilometers. In detail, and now we once again They received confirmation from the manufacturer. Oil change - needed.

Thirdly, you need to go carefully. Worn accelerate sharp accelerations (especially on cold oil), towing and towing in dirt. These are all capital truths.

***

By the way, how much is the restoration of automatic transmission? Nobody calls a specific figure in ZF. It all depends on how much the "automatic" was ruined and margin received by a mediator or dealer center. However, it is believed that for 30 thousand rubles a qualified master will agree only to disassemble the box, rinse it and raise it again. And then as a card will be lying ... diagnostic, of course.

Damage and malfunction of housings, friction groups, bushings, clips, calipers, planetary rows, pump and other fur. Parts.

Signs:

The car is either not moving at all or constantly sinks (there is no overclocking on the engine rolling speed), fault box machine either a complete lack of switching, noise from the machine, etc.

Diagnostics:

Primary - removal of the pallet with automatic transmission and its inspection for the presence of metal and other alien fractions in it (chips, metal dust, plastic debris, etc.). Inspection of oil in order to detect or not in it, particles of antimony, air, combustion products and other destruction. Then the dissemination of the machine for a thorough visual study of each individual details in order to identify all sorts of damage. Also, with the help of the scanner, it is made, but due to the fact that such an inspection can also give errors, as a rule, it will be inaccurate.

How to check the oil in the automatic transmission In most cases, it is under the hood, but in modern cars still practiced to "hide" it in order to eliminate cases breakdowns automatic transmission associated with the human factor. So it is not at all necessary to look for it and blame the manufacturer and / or the past owner in this, everything is much easier - the installation of stationary probe on certain types of automatic transmission is not provided. If it is not - you need to use the universal service probe. But! On some cars, even universal service probe is not provided, and can be carried out strictly in specialized service centers. In order to certainly know the peculiarity of your automatic transmission, we recommend on our website.

Malthotransformer malfunction: disruption of the piston sealance and failure of the main blocking friction. The destruction of the turbine, overtaking coupling, blades, breaking the drive slots and so on.

Signs:

The machine does not move and slides on any of the speeds. The noise and crackle from the front of the box are heard. There is no fifth transmission.

Diagnostics:

"Lock error" can issue an electronic diagnostics scanner. On the automatic transmission of the hedgehogs from steel dust and shallow shavings, friction dust in the pallet.

Underwater transformer device

Hydraulic stove (hydroblock) with its mechanical problems.

Signs:

Rigid and protracted shifts, blows and sometimes no switching to one of the boost gears.

Diagnostics:

The scanner in this case rarely gives the correct result, here it often only helps the full disassembly of the block and inspection of the fur. Plungers in order to detect burrs and wear on them, it is also necessary to inspect valves and balls for wear and check the parameters of the elasticity of the springs.

For the last, it should be noted that only an experienced specialist is able to accurately determine and eliminate any defect of your automatic transmission.

The car equipped with an automatic transmission is easy to handle: the driver selects the corresponding mode for the trip, and the mechanism already switches the speed itself. There is a huge load on the transmission, which, in combination with incorrect operating conditions, leads to serious breakdowns. Leading automotive companies invest a lot of effort into developing and improving technology production technologies to achieve a maximum life and creation of a truly reliable design. The need for the first serious repair of equipment should occur no earlier than 15,000,000 mileage kilometers.

The nature of the breakdown says a unique combination of "symptoms", which can express themselves in different ways: in refusal vehicle Go forward / backward, in jokes when driving, slipping and uncharacteristic to work a knock. For example, when the hydrotransformer fails, the car begins to move the jerks at the time of shifting gear. The more serious breakdown, the more noticeer it shows itself. In addition, every car enthusiast should know: Malfunctions automatically have a progressive character, and if they do not prevent them in time, there are quite a few funds for the repair of all equipment. Trust Repair best of all highly qualified specialists who, having conducted diagnostics, will differ due to the formation of malfunctions in the device.

If the vehicle breakdown occurred on the path (speeds independently do not switch or blocking on any of the gears), it is necessary to cause a tow truck. Movement on the vehicle with a breakdown in the transmission is prohibited, because A serious damage to the actuator can occur.

To help car enthusiasts, engineers provided many brands of cars additional sensorswhich show the estimated (but not final) cause failure: low level Oil, equipment overheating, etc. Such a method for diagnosing faults does not allow one hundred percent result. To determine the worn node, a visual inspection of the transmission, which is possible only after opening the gearbox.

The most frequent causes of damage to automatic transmission

Kulis gearbox

Problem mechanisms of an old type automatic transmission, having a mechanical communication with transmission with a gear selector, is a lever scene. The presence of such a problem is the emergence of difficulties in the transmission of the "automat". In this case, to eliminate the faults, the lever and the selector itself will be replaced. Most models have good access to problematic placeTherefore, dismantling the gearbox to replace worn equipment will not need. This greatly facilitates repair work.

Low oil level and leaks on the device

The frequent "symptom" malfunction of the automatic transmission protrude oil leaks on the case of the device, indicating the wear of the sealing gaskets. In this case, it is advisable to independently replace them (this procedure does not cause complexity) and change the oil in the "Automatic". Car enthusiasts are encouraged to make a visual inspection of the box for dried oil at least once every 2 thousand kilometers of run.

Transmission control unit

In the event of failures in the operation of the block, it can be noted that the speed switching occurs in the usual mode, but with overpriced or, on the contrary, low speeds. At a certain point, the "automatic" can occur. Repair of the control unit is to replace the problem mechanism and careful inspection of the electrical part of the gearbox.

Worn gear gearbox

Metal chips on a magnet in a crankcase pallet

Broken oil pump

What needs to be taken to avoid problems with automatic transmission?

Like any other mechanism, the automatic transmission requires compliance with the elementary rules of operation. Her fast wear It is easy to explain to the irregular replacement of the transmission oil and, as a result, the rapid heating of the overloaded device nodes. Elements that lack oil lubricant quickly wear out and entail serious breakdowns. In addition, the old oil negatively affects the work of solenoids, the dismantling of which will cause great difficulties - getting close to them without removing the "automatic" is almost impossible.

In harsh weather conditions, an automatic box requires careful warm-up, otherwise the mobility of the transmission parts will be broken. Aggressive driving style also negatively affects the operation of an automatic mechanism: due to the long operation of the motor on increased turns The process of burning frictions begins. Switch the speeds and gas is needed smoothly, in order to significantly increase the life of the transmission mechanism.

By itself, the replacement of worn items does not represent much difficulty. But the main problemWith which the repairmen will face is the need to remove the "automat" from the car. This can be done only on a special device. Removing the gearbox will allow auto mechanics to open it and determine the object of breakage, after which it will be necessary to produce high-quality repairs to eliminate all faults. Despite high cost ACP repair services (it is explained by the complexity of the process), it is impossible to save on transmission. Having broken once, say, in the presence of a simple oil patent, you will save your car from overhaul further.

Malfunctions automatic transmission	Methods for their elimination
Slug car in the first speed. At the same time, the rear speed works without problems	Replacement of the rings and cuff cuffs the coupling. The valve of the torque converter must be cleaned of contamination
The first speed is working, the rest (including rear) do not function	Replacing the friction disk and the worn piston of the coupling is required. It is worth checking the state of the coat of the ring of the coupling, in the case of its cliff - replace
The car does not move. To switch gear reacts a strong push	The torque converter should be replaced. You should also check the level of transmission oil, add it if necessary. Oil filtermay have come into disrepair and requires replacement
Only 3rd speed works	It is necessary to replace the piston cuff and friction disks. Check for contaminants of the hydraulic valve. If the specified actions did not help, the car must be delivered to the nearest service center. When you turn on the emergency gearbox there is a probability of detection of a serious breakage
Car does not work reverse gear	It is necessary to check the state of the brake ribbon, as well as the entire car braking system
The car does not respond to switching the gear. No jolts and movement	Perhaps the transmission oil ended. Check the level and decrease it if necessary. Clean the filter grid, the hydraulic valve and check the state of the solenoids.
When moving on the car, the vibration and a strong hum of the "automatic" is tangible. The more turns, the stronger the hum	Replacement of bearings required
Ringing the usual step of switching speeds	Adjust the cable throttle valve And clean the filter from pollution. If the problem persists, replace the throttle valve
With a long-lasting lift, the car is noticeably ranks, the "automatic" box includes a reduced transmission.	Low oil level can lead to a similar problem. It should also be inspected with the subsequent replacement of brake tape, friction discs and couplings. Oil pump replacement
Turning on the first transmission leads to a challenge of the car, with a set of slip speeds ends	Shaft "Machine" slipping. Replacement of the slope of the hub of the turbine wheel is required. Piston cuff breaks
Gear shift causes a car slip	Clean the filter and change the transmission oil. If it does not help, it means you need to replace the oil pump
Each speed switch is accompanied by noncharacter	Replacement of friction discs and brake ribbon
The immentable car moves without visible faults, but as soon as the heating of the transmission oil occurs, the vehicle slip is observed.	Oil replacement is necessary: \u200b\u200bwhile it is in a cold "state, it is denser compressed friction discs. Heating reduces its pressure and viscosity, leading to such problems
For harsh pressed on the gas pedal, the automatic box does not switch to reduced gear, and the engine turnover does not increase	The fault lies in the operation of the motor system. It is necessary to immediately contact the car service
With visual inspection of the car, iron "fragments" was found, with a diameter of 1 mm, in the pallet of the vehicle	The planetary gear fails. Replacement of details required
Transmission oil foams, there was a change in its color to an unnatural	Water got inside the "automat", the oil change is necessary
Turning on the speed causes the motor shutdown, when holding the pedal of gas movement there is	The torque converter is faulty. It requires its replacement
In the pallet there are aluminum "fragments"	Replacing the planetary gear, sliding bearing
On the pallet you can see plastic "fragments"	It is necessary to inspect all plastic components of the automatic transmission
When moving the vehicle noticeable grinding of metallic origin	The gears and the differential bearings failed. Need them to replace
When examining the car in its pallet, the magnetized rollers can meet	This malfunction speaks of the destruction of the roller bearing

The appearance of incomprehensible noise in a box, a car slip, noticeable vibration and substantial deviations from ordinary "behavior" talk about the presence in the automatic transparency facility automatic transmission. In the event of the first signs of breakage, it is more expedient to contact the service center for help.

The long-term use of a car with a broken "machine" will result in full blocking of the box, and then the driver will have to pay not only the cost of repair, but also the towing services.

"Electronic" problems of automatic transmission

In electronics "Machine" often faults often appear, but fortunately by car owners, when they are discovered, dismantling and dismissal of automatic transmission is discovered. The main "electronic" problems should be attributed:

• Instability of the sensors of the "automat": the car either periodically enters emergency mode (while driving) and independently comes out of it, either goes into emergency mode finally and does not come out of it even after disconnecting the power unit.
• The control unit fails: the gearbox does not leave the emergency mode for a long time.
• Capturing wiring causing a reaction to switching the gear "automaton". The car is in constant emergency mode or periodically leaves it, but does not react to the driver's actions.
• Faulty solenoids, pressure electroregulator: the car periodically "forgets" to switch transmissions, when the shifts are noticeable, the shocks and mechanical grinds are noticeable, in some cases the vehicle switches to the emergency mode and independently leaves it.

All listed malfunctions of the automatic transmission do not require "surgical intervention" of auto mechanics, i.e. To diagnose them, you do not need to disassemble the automatic box. It suffices to take advantage of a special scanner or measure the electrical parameters (inductance, electrical resistivity, etc.)

The impossibility of switching speeds

With some types of breakdown, the gearbox does not switch speed. To deal with what the reason, having only indirect signs, is hard, however, it is possible. So, the automatic transmission does not include speeds, most often, for the following reasons:

1. Low level of transmission oil. A low oil level is evidenced by the challenge of the car at the beginning of the movement, pressing when the gear is turned on, the complete absence of vehicle movements. In combination with a faulty torque converter, the absence of the necessary amount of oil can lead to the destruction of the main elements of the transmission mechanism. The actions algorithm is very simple: at the first signs of faults - to add oil, change the filter, with complications - to seek help from highly qualified specialists.
2. Wear friction discs. The wear of these elements says the incomprehensible behavior of the car: either it moves forward, but there is no reverse gear, or everything happens exactly on the contrary - the rear gear is, and the movement forward is not carried out. In addition, there may be a slip after heating the transmission fluid. Friction disks, going out, form dust, which settles on the automatic transmission filter, scores it, causing a drop in the main pressure.
3. Open brake ribbon. The brake tape can also cause serious problems in the operation of the automatic transmission. To diagnose the wear of this element, it is necessary to make a visual inspection and examination of the whole brake system. The driver must follow the state of this mechanism to maintain the required level of car safety.
4. Shift shifting valve. This malfunction is easily eliminated - just clean the valve from dirt and install it back.
5. Failure in the operation of the hydrotransformer. The torque converter is a single unit, not to be dispersed. If one of its components failed, then the replacement of the entire device is required. With the proper operation of the car, the hydrotransformer will last 150-200 thousand mileage kilometers.

Conclusion

Wrouders of cars with automaton should remember that the repair of this device is a very heavy and expensive "pleasure". In order to avoid severe consequences, it is necessary to implement in a timely manner. maintenance vehicle:

on time to change transmission fluid and filters listen to visual inspection of the gearbox and motion elements replace worn or destroyed components

Compliance with these simple rules Allows motorists to extend the service life of the automatic transmission of your car.

AUTOLEEK.

Our chief Principle: If you have the opportunity - it is better to do without welding. But if still without welding it is impossible, then you need to provide:

• - Strength (it should be no worse than new Detail)
• - Tightness (the most details and in conjugation with neighboring)
• - Durability
• - restoration of geometric sizes (may change after welding)

If this fails, it is better not to take for welding.
Based on our, more than 14 years experience, we can say that you can restore almost everything - the question is only in financial feasibility and timing.
Examples of some of our works:

1. Welding of cylinder blocks (BC).

1.1. Repair of BC beds after improving inserts and in the occurrence of cracks on the supports of the bed of crankshaft.

The reason is the drop in oil pressure. Most often - on commercial vehicles with big mileage. As an example, we give the most difficult case: damage the bed of BC bus "Mercedes-Benz Sprinter" (OM engine 611). After the appearance of the characteristic "strain" engine, the car managed to make another 10 flights. As a result, the crankshaft after the jamming broke, and one of the supports was collapsed. At the same time, the liners in the remaining 4 supports were checked ... That's what happened in the end:

The bed is additionally enhanced by setting studs instead of bolts. Cost of work - 14 000 rub.

Another common case is the engine of the engine liner heavy truck (any brand, incl. MAZ, KAMAZ). In this case, without harvesting supports using special material not enough…

It is much easier in terms of welding technology to restore the supports of the aluminum BC. Although the case with BMW (engine M52) was not so simple - the cracks on the bed were out of the top of the BC and passed through the partitions between the cylinders ...

The cost of all works - 55 000 rubles.

1.2. Welding spacing and cracked BC

The most "heavy" losses carries a BC after an accident or when one or several rods are cut. At the same time, there are breakdowns or chips of the block itself and restore the performance of the most difficult - after all, conjugate details suffer. So, when eliminating a large holes in the block of the block, we had to do a lot of concomitant works ...

The most difficult to eliminate cracks in the cooling shirt and especially in the "inconvenient" cast iron blocks. The case below is special: after welding it was necessary to restore the performance of the "wet" sleeves. So: the block of cylinders of the Chinese truck - the cracks of partitions between the cylinders with damage to the belt, for which the wet sleeves are compacted ...

Restoration of the landing of "wet" sleeves on the upper and lower (under the rubber rings) the landing holes included: milling of the docking plane of the BC, pierce support for the sleeve per height (with an accuracy of 0.01 mm), repair of sealing belts (welding, boring)

Restoration of the landing of "wet" sleeves on the upper and lower (under the rubber rings) the landing holes included: milling of the docking plane of the BC, pierce support for the sleeve per height (with an accuracy of 0.01 mm), repair of sealing belts (welding, boring)

All sleeves are fitted at the height of the speech above the plane of the BC. The unit is restored, the cooling shirt is crimped. The cost of all works - 52 000 rubles.

In this section, not all cases of repair of cylinder blocks with welding are illustrated, but only the most complex of them. We successfully eliminate other BC defects:

• - a crack on the hole of the oil supply on the whole bed of the crankshaft - 7 000 rubles;
• - damage to the main maslochannel of the BC (when the roller break) is from 2,000 to 7,000 rubles;
• - Open the threaded bobs of the engine pillow - 1 500 rubles. behind the bump
• - crack in a threaded well (thread mounting the head of the block to the BC). Cost for aluminum BC - 5,000 rubles;
• - Damage to the docking plane of the BC (with a block of block) - from 1,500 to 5,000 rubles.

Everything else we try to repair without applying welding, but using our experience in metalworking.