变速箱作为机械传动的核心部件，长期运转难免出现齿轮、轴承、轴类等零件的磨损，处理磨损问题需结合损伤程度与部件特性，通过精准检测、分类修复与严格校验，恢复其传动精度与运行稳定性。

　　As the core component of mechanical transmission, the gearbox is inevitably subject to wear and tear on gears, bearings, shafts, and other parts during long-term operation. To deal with wear issues, it is necessary to combine the degree of damage and component characteristics, and restore its transmission accuracy and operational stability through precise detection, classification repair, and strict verification.

　　磨损检测是修复的前提，需通过拆解与精密测量锁定问题。将变速箱完全拆解后，先用专用清洗剂去除零件表面的油污、铁屑，借助放大镜观察齿轮齿面是否有点蚀、剥落或阶梯状磨损，轴承滚道是否存在划痕、凹陷，轴颈表面是否出现磨痕或椭圆度超差。使用千分尺、百分表等工具测量关键尺寸：齿轮的齿厚偏差若超过 0.15 毫米，可能导致啮合间隙过大；轴承内圈与轴的配合间隙若超过 0.05 毫米，会引发运转异响；轴类零件的直线度误差若超过 0.03 毫米 / 米，需进行矫正。同时，检查同步器锥环、换挡拨叉等易损件的磨损情况，如锥环内锥面的螺纹槽是否磨平，拨叉与槽的配合间隙是否超标，这些细节直接影响换挡平顺性。

　　Wear detection is a prerequisite for repair, and locking issues need to be addressed through disassembly and precise measurement. After completely disassembling the gearbox, use a specialized cleaning agent to remove oil stains and iron filings from the surface of the parts. Use a magnifying glass to observe whether there is pitting, peeling, or stepped wear on the gear teeth, whether there are scratches or dents on the bearing raceway, and whether there are wear marks or ovality deviations on the journal surface. Use tools such as micrometers and dial indicators to measure key dimensions: if the tooth thickness deviation of the gear exceeds 0.15 millimeters, it may lead to excessive meshing clearance; If the clearance between the inner ring of the bearing and the shaft exceeds 0.05 millimeters, it will cause abnormal noise during operation; If the straightness error of shaft components exceeds 0.03 millimeters per meter, correction is required. At the same time, check the wear of vulnerable parts such as the synchronizer cone ring and shift fork, such as whether the threaded groove on the inner cone surface of the cone ring is worn flat, and whether the clearance between the shift fork and the groove exceeds the standard. These details directly affect the smoothness of shifting.

　　针对不同磨损程度，修复方式需分级处理。轻度磨损（如齿轮齿面仅有轻微划痕、轴颈表面光洁度下降）可采用研磨抛光技术：用细砂纸或研磨膏手工打磨，配合专用研磨工具保持零件原有的几何形状，避免过度磨削导致尺寸精度丧失。例如，对轴承座孔的轻微磨损，可用珩磨工具进行内孔研磨，恢复其圆度与表面粗糙度，确保轴承装配后运转平稳。中度磨损（如齿轮啮合间隙超标但齿根未受损、轴颈出现均匀磨损）可采用电刷镀或激光熔覆技术：电刷镀通过电解作用在磨损表面沉积一层金属镀层（如镍基合金），厚度控制在 0.05-0.2 毫米，经打磨后恢复配合尺寸；激光熔覆则利用高能激光将合金粉末熔覆在磨损部位，形成与基体结合牢固的耐磨层，适用于承受较大载荷的齿轮、轴类零件，熔覆后需通过数控加工保证精度。

　　For different degrees of wear, the repair methods need to be graded. Mild wear (such as only slight scratches on the gear tooth surface or a decrease in the surface smoothness of the shaft neck) can be treated with grinding and polishing techniques: manually polish with fine sandpaper or grinding paste, and use specialized grinding tools to maintain the original geometric shape of the part, avoiding excessive grinding and loss of dimensional accuracy. For example, for slight wear of the bearing seat hole, honing tools can be used to grind the inner hole, restore its roundness and surface roughness, and ensure smooth operation of the bearing after assembly. Moderate wear (such as gear mesh clearance exceeding the standard but without damage to the tooth root, and uniform wear on the shaft neck) can be treated with electric brush plating or laser cladding technology: electric brush plating deposits a layer of metal coating (such as nickel based alloy) on the worn surface through electrolysis, with a thickness controlled at 0.05-0.2 millimeters, and after polishing, the fit size is restored; Laser cladding uses high-energy lasers to fuse alloy powder onto the worn area, forming a wear-resistant layer that is firmly bonded to the substrate. It is suitable for gear and shaft parts that can withstand large loads, and the precision needs to be ensured through CNC machining after cladding.

　　严重磨损或结构损伤的零件需果断更换，避免修复后留下隐患。当齿轮出现断齿、齿面剥落面积超过 20%，轴承滚道裂纹或保持架损坏，轴类零件出现弯曲变形或裂纹时，必须更换新件，且新件需与原规格一致（包括材料牌号、热处理硬度等），如齿轮常用 20CrMnTi 渗碳淬火（表面硬度 58-62HRC），轴类多用 45 钢调质处理（硬度 220-250HB）。更换同步器、离合器片等易损件时，需同时检查相关配合部件，如同步器锁环与齿轮锥面的接触面积需达到 70% 以上，确保换挡时能迅速同步。装配新件前，需进行清洗与预润滑，避免杂质混入或干摩擦导致二次磨损。

　　Parts with severe wear or structural damage should be replaced promptly to avoid potential hazards after repair. When gears have broken teeth, tooth surface peeling area exceeds 20%, bearing raceway cracks or retaining frame damage, and shaft parts have bending deformation or cracks, new parts must be replaced, and the new parts must be consistent with the original specifications (including material grade, heat treatment hardness, etc.). For example, gears are commonly treated with 20CrMnTi carburizing and quenching (surface hardness 58-62HRC), and shafts are often treated with 45 steel quenching and tempering (hardness 220-250HB). When replacing vulnerable parts such as synchronizers and clutch plates, it is necessary to check the relevant mating components at the same time. For example, the contact area between the synchronizer lock ring and the gear cone surface should reach more than 70% to ensure rapid synchronization during gear shifting. Before assembling new parts, cleaning and pre lubrication are necessary to avoid impurities or dry friction that may cause secondary wear.

　　修复后的装配与校验是保障性能的关键。按照拆解相反顺序装配，所有零件需涂抹专用变速箱油（按车型要求选择矿物油或合成油），轴承、齿轮的安装需使用专用工具（如压套、拉马），避免蛮力敲击导致零件变形。装配过程中，需多次测量啮合间隙（齿轮副侧隙通常为 0.1-0.3 毫米）、轴向窜动量（轴类零件一般不超过 0.15 毫米），通过调整垫片厚度确保参数达标。完成装配后，进行台架试验：模拟不同转速与载荷，测试变速箱的换挡灵活性、运转噪音（空载时噪音应≤75 分贝）、油温变化（连续运转 1 小时后油温不超过 80℃），若发现异常响动或换挡卡滞，需拆解检查并重新调整。

　　The assembly and verification after repair are key to ensuring performance. Assemble in the reverse order of disassembly, and all parts need to be coated with specialized transmission oil (choose mineral oil or synthetic oil according to the requirements of the vehicle model). The installation of bearings and gears requires the use of specialized tools (such as press fit and pull tab) to avoid deformation of parts caused by brute force impact. During the assembly process, it is necessary to measure the meshing clearance (usually 0.1-0.3 millimeters for gear pairs) and axial displacement (generally not exceeding 0.15 millimeters for shaft parts) multiple times, and ensure that the parameters meet the standards by adjusting the thickness of the gasket. After assembly, conduct bench tests: simulate different speeds and loads to test the shifting flexibility, operating noise (noise should be ≤ 75 decibels when unloaded), and oil temperature changes (oil temperature should not exceed 80 ℃ after continuous operation for 1 hour) of the gearbox. If abnormal noise or shifting jamming is found, it needs to be disassembled, inspected, and readjusted.

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