Alfa Romeo 5 speed hydraulic clutch transmission rebuild.
Don't want to do it yourself? www.bradcorestorations.com/
Sorry for the noise in the background in the middle of the video, it goes away later.
Will post the final assembly soon and leave a link to it.
Key points:
Do not pry on surfaces. They are supposed to be machined to seal without any gaskets or RTV. Any damages will compromise the seal. I choose to use a little bit of RTV (red) when reassembling nevertheless.
Do keep notes and carefully detail where shims go. They will prevent sloppiness in the gearbox. The procedure to determine shims can be very time consuming and frustrating.
Catch the parts when you press them out!!!
Use the correct tools for the job. Once the bell housing is off, you will need 13mm wrench, 13mm socket, 12mm socket, 10mm socket, 32mm socket, mallet, flat head screwdriver (don't use it to pry housing apart), hydraulic press or gear puller, retaining ring tool, shop rags, mineral spirits (lacquer thinner), assembly grease/oil, zip ties.
00:50 - Removal of rear cover nut
2:18 - Removal of rear cover
4:15 - Removal of 5th gear selector
5:12 - Removal of selector shafts plunge
5:20 - M6 bolt, 10mm socket (correction)
6:20 - Removal of 5th gear selector shaft
7:05 - Splitting of case
7:43 - The right oil level mark is actually by the fill plug, you can see a thin line
8:06 - Brief explanation on how the transmission works
14:23 - Lightened gears 1 and 2
15:50 - Remove shafts from casa
17:26 - Explain selector rings exchangeability
18:05 - Remove shaft retaining ring for 3rd gear
18:53 - Press out 3rd gear -- Make sure to catch the parts!!
20:07 - Remove 5th gear and rear bearing
21:04 - Press out reverse gear
22:39 - Remove woodruff key
22:52 - Press out intermediate bearing
23:28 - Remove 1st gear
23:47 - Press out 2nd gear
25:57 - Replacing gears 2-5 synchromech
26:49 - Dog gears replacement
27:40 - Press out dog gears
28:19 - Gear 1 synchromech mechanism and dog gear
29:37 - Gears 2-5 synchromech mechanism "blow up"
30:54 - New synchromech
Great video. Super important stuff covered nicely. We in the Alfa community would like to see more
Thank you this video. This is the first time that I've understood how a manual gearbox actually works.
Really helpful stuff here. This is a great video on the Alfa gearbox. So much easier to understand than a workshop manual. Very timely too as I need to remove and look at the reverse gear in a week or so - keeps slipping out of reverse. Thanks.
So helpful! I've pulled mine apart already but was never totally sure what was what...thanks for the clear description.
very useful. keep posting Alfa stuff :)
Nice work. I will be going for it myself.
Excellent! Great info, thank you for sharing!
Great explanation! Thanks 🙏
Thanks man that's a great help.
Tiago, I rebuilt my transmission last week. The only problem I was having is the infamous Alfa Romeo 2nd gear grind. I put in a new 2nd gear inner and outer syncro and gear dog ring. The engine is in a machine shop so its going to be a couple of weeks before it is all back together, but just shifting the gear shift, all the gears are smooth except going into 2nd gear. Did I do something wrong or is it because the parts are all new on 2nd so it is very tight now??? I am 100% sure I took the gear box apart and put it back together correctly. Do you have any advise, because if I did something wrong I want to redo it before the engine gets back.
Sounds like you were able to put everything back together. I'd say if you're confident everything went in proper order, it's probably just because everything is new.
Very nice video. My Spider transmission will not hold in reverse. It pops out with considerable force. I can hold it with my hand. I the start of the video you had trouble removing the back casing until you removed the two shimmed opposing cylinders at the top of the transmission near the shifter. Could that adjustment be causing my problem? Any suggestions. Oh if that is the problem can i adjust in the car? Any info on this would be greatly appreciated. Thanks
I have the same problem, please let me know if you solve the problem.
Yes the shimming has a great effect on selecting the gears. are you sure that in your case the shims are, as they were?
Well, clearly I don't check my youtube account as often as I should! There is a chance it's the shims. However, the main function of the shims is to prevent it from sliding from 5th straight to reverse. What I have noticed in the past was something as simple as the shifter boot (or boots, depending on what model) being so stiff that they'll work to push the shifter out of gear! Hope that helps!
Tiago, I was racing and I let the clutch pedal out before I shifted the shifter into 3rd gear and so I ended up slamming the shifter into 3rd with my foot off the pedal. Now the car will not engage into 3rd gear. What did I do and how do I fix it. Please let me know.
Ugh! That doesn't sound good, sorry to hear that. The best way to find would likely be taking it apart but chances are something came off place. Hopefully nothing broken!
Where do you get your parts?
bradcorestorations.com or classicalfa.com
bradcorestorations.com or classicalfa.com