Vin's S4 Transmission Rebuild for Dummies - Page 2 - Alfa Romeo Bulletin Board & Forums

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post #16 of 93 (permalink) Old 03-19-2017, 12:46 AM Thread Starter
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Using a 12mm socket, loosen the bolt
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Remove the bolt/tab/alignment washer
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Here are some nice pictures I found on the BB
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Here we can see the alignment tab and fork are grooved. This helps us later.
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #17 of 93 (permalink) Old 03-19-2017, 12:52 AM Thread Starter
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Now you can pull the shift rod out.
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Remove the fork
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Now you can remove the mainshaft.
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Here we can see that in my S4, there are no O rings to be changed mentioned in other threads. As well, we can see the jelley bean or peanuts or ????. If you aren't removing the other 2 shift rods and forks, you don't need to worry about these. Somehow 1 fell out on me and I was lucky to find it on the bench, so we will see how they come out and go back in later.
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.
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post #18 of 93 (permalink) Old 03-19-2017, 01:15 AM Thread Starter
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Remove the input shaft / 4th gear by just pulling it straight out
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4th gear bearing. This might stay on the shaft, like mine, or stay in the 4th gear but find it and store it safely.
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Move the input shaft / 4th gear to a bench vise so you can work on it. I know, I need to buy vise jaw protectors.
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And here we have the ever famous, dreaded, large snap ring found on every gear except reverse. Note that one end is flat and the other has a tab or an ear. We use the tab/ear for removal and installation.
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.

Last edited by Vintre; 03-19-2017 at 03:21 AM.
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post #19 of 93 (permalink) Old 03-19-2017, 01:24 AM Thread Starter
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To replace the syncro rings, you must remove the snap rings. I bought these large, straight tip, snap ring pliers from Princess Auto (Canadian version of Harbor Freight) for $15. Didn't know how they would work, but gave them a try. I was worried about removing the large snap ring as you read so much about how hard it is to remove them. I talked to papajam and he taught me a way to remove them safely and somewhat easily.
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Start by spreading the snap ring, pushing the ear against gear, keeping it in the groove and lift the other side out of the groove.
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Now, with your hand over the snap ring, in case it goes flying, continue to spread the snap ring just enough to keep working it around, out of the groove.
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And there you have it! No fuss, no muss, no mess.
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #20 of 93 (permalink) Old 03-19-2017, 01:47 AM Thread Starter
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Here is what that snap ring is holding in. The assembly is the same for 2nd - 5th. 1st is a little different, but we are going to change that during the 1st Gear Fix. Note the position of the quadrants ( the 2 top hat looking things). The small one is pointed into the centre of the gear and the larger one is pointing out of the syncro ring.
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All the parts just lift out. Here is the outer syncro ring (cut out at 12 o'clock), the 2 quadrants, one small one large, and the 2 check straps that go from quadrant to quadrant. All parts go in the baggie for later!
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Remaining mainshaft
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3rd Gear end
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.

Last edited by Vintre; 03-19-2017 at 01:50 AM.
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post #21 of 93 (permalink) Old 03-19-2017, 01:58 AM Thread Starter
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Remove the 4/3 syncro hub by just sliding it off
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I borrowed this 12T press from a friend. It did the job, but I would recommend the 20T. The 12T did the job, but at times it seemed weak.
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I bought a 3" gear puller from Princess Auto. It was the biggest one they had. Like the press, it was OK, but I would recommend a bigger one if you can get it.

So, onto the first press !!!!!!!!

With the olive facing up, place the puller under the reverse gear (straight cut gear).
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I placed a cushioned catch bin under the press in case I wasn't able to support the shaft. After this first press, I didn't use the catch bin. I was able to support the shaft.
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.

Last edited by Vintre; 03-19-2017 at 03:27 AM.
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post #22 of 93 (permalink) Old 03-19-2017, 02:08 AM Thread Starter
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1st pull, you get a lot of parts. Sorry I dont know all the names for each part but I kept track of each one and the order they came off.
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5th gear assembly
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #23 of 93 (permalink) Old 03-19-2017, 02:11 AM Thread Starter
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Double bearing
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5th syncro hub
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Syncro Ring / Reverse Gear
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #24 of 93 (permalink) Old 03-19-2017, 02:25 AM Thread Starter
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Mainshaft at this point
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Remove large Woodruff key
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Place gear puller under bearing
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Bearing pulled
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #25 of 93 (permalink) Old 03-19-2017, 02:29 AM Thread Starter
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Bearing has a cap that goes in the middle of the bearing
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Remaining mainshaft
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Olive up, place the gear puller under the large 1st gear. Note the rods on the gear puller have changed. The 3" puller is too small for 1st gear. Luckily I had these rods from the front suspension work I did.
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Puller under 1st gear
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #26 of 93 (permalink) Old 03-19-2017, 02:38 AM Thread Starter
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1st Gear Pull
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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post #27 of 93 (permalink) Old 03-19-2017, 02:42 AM Thread Starter
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Olive up, place the gear puller under 2nd gear.
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2nd Gear pull
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2/1 syncro hub
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.
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post #28 of 93 (permalink) Old 03-19-2017, 02:46 AM
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Garage
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Thank you very much

Current cars 1975 spyder under resto, 1971 spyder needs work, 1972 GTjunior fully restored, 1 complete rolling shell spyder.exit 1989 75 T/S sold
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post #29 of 93 (permalink) Old 03-19-2017, 02:52 AM Thread Starter
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2/1 syncro ring
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2nd gear
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To remove 3rd gear, place in bench vise to remove small snap ring
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.
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post #30 of 93 (permalink) Old 03-19-2017, 02:55 AM Thread Starter
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Input shaft up, place the gear puller under 3rd gear.
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3rd gear pull
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4/3 syncro hub and 3rd gear
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1991 Spider Veloce - Red on Tan - Rosa Bionda
1987 Spider Quadrifoglio - Red on Grey - Rosa - Sold
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Honey, this is the last thing I have to do, then I'm finished. It'll just be a minute.
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