Rebuilding, and some questions for the experts
QUESTIONS FOR THE EXPERTS:
1) what size is the factory Alfetta GT/ GTV rear sway bar?
2) do ALL Alfettas use 8mm bolts to fasten the brake rotors to the driveshafts/halfshafts? It seems the CV's use 8mm bolts compared to 10mm all around on V6's.
My Dad reports that the car has no problem chirping the tires into 2nd gear...such a strong car deserves a nice tight trans! My test drive reveals a slightly crunchy 2nd gear when downshifting, and that just won't do. Also hear a noisy rear wheel bearing. It's kind of muddy/greasy under there so I'm going to pull the DeDion and refresh it all I guess...
Time to rebuild a transaxle! Core came from a late sedan which as far as I know is identical to any late Alfetta (finer pitch teeth compared to early, slightly wider flange shaft bearings). BUT - it has 10mm holes for stub axle flanges? W THE F?!? I thought all Alfettas were 8mm. This transaxle had never been apart and the flanges are certainly original. Fluid drained clean and didn't find any big chunks missing.
Anyway, core transaxle gets a deep clean and disassembly reveals only minor needs. A couple chipped dog teeth, worn synchros and sliders. Bearings like new, teeth like new on gears, diff super tight like new. Centerline provided new Italian seals for input shaft, selector shaft, and stub axles at the flange. Be sure to use your dial indicator to check the pinion height!
For the trans build, I got some new parts from Centerline and dipped into my spares for the rest. New synchro ring on 1, 2, and 3 gear with an OEM Goetze synchro ring on 2nd gear and standard "aftermarket" units on 1 and 3. I used a 5th/R synchro slider on 1/2, another 5/R slider on 3/4, put my 3/4 slider on 5/R. Good used 5th gear dog teeth for 2nd gear. Converted the 1st gear synchro to the bi-directional style with a stop quadrant and brake strip from a donor 2nd-5th gear. 4th and 5th gear synchro rings were like new so were re-used. Diff bearings like new, no detectable wear so left that alone. Case was re-sealed with Permatex Gray. Polished the throwout bearing tube on the buffing wheel so this trans should be good to go.
Alfas first, then everything else.