Vin's S4 Transmission Rebuild for Dummies - Page 4 - Alfa Romeo Bulletin Board & Forums

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post #46 of 99 (permalink) Old 03-19-2017, 06:31 PM Thread Starter
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Took some pressure and came off with a SNAP, but off it came. Here you can see that the inside of the dog teeth is keyed as well as the top of the gear.
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Gear and dog teeth separated. I will show how to install the "new" dog teeth next when we do the 1st Gear Fix.
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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 #47 of 99 (permalink) Old 03-19-2017, 07:21 PM Thread Starter
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1st Gear Fix

Ok, onto the 1st Gear Fix. Many thanks to 60sRacer for this thread First Gear Fix.

1st gear as pulled from the mainshaft
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Remove the snap ring. Here you can see the difference from the other gears. The large quadrant (top hat) is different shape. There is only 1 check strap and there are 2, not 1, cutout on the dog teeth ring.
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Syncro internals from 1st vs others
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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 #48 of 99 (permalink) Old 03-19-2017, 07:25 PM Thread Starter
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I am using this transmission assembly lube to help with the assembly.
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Put a bit of lube on the gear. I bought a paint brush later.
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Put a bit of lube on the dog teeth ring
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Align the dog teeth on the gear so that the cut out lines up with or as close to the oil galley on the gear. Both can be seen here, 12 O'clock.
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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; 03-20-2017 at 01:08 AM.
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post #49 of 99 (permalink) Old 03-19-2017, 07:43 PM Thread Starter
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Over on the shop press use an appropriate plate that will cover the top of the dog teeth ring.
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Voila! Newly pressed dog teeth on 1st Gear
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Place NEW syncro ring on so that the cut out of the syncro ring (seen at 6 o'clock) is directly opposite the cut out of the dog teeth gear (seen at 12 O'clock).
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Assemble the small quadrant so that it points into the dog teeth ring and the large quadrant points out of the syncro ring. Oh yeah, don't forget the 2 check straps.
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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 #50 of 99 (permalink) Old 03-19-2017, 07:47 PM Thread Starter
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Replace the snap ring.
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And there you have it, 1st gear with new dog teeth, new syncro ring and with THE FIX!
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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; 03-20-2017 at 01:10 AM.
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post #51 of 99 (permalink) Old 03-19-2017, 07:58 PM Thread Starter
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Remove and replace all of the the dog teeth rings as you need.

Replace all of the syncro rings (we just did 1st gear) and re assemble gear assemblies.

2nd gear replaced dog teeth and syncro ring replaced.
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3rd gear replaced dog teeth and syncro ring replaced. No picture !

4th gear will need to back into the bench vise to do all the work.
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4th gear syncro ring replaced
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5th gear syncro replaced
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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; 03-20-2017 at 01:11 AM.
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post #52 of 99 (permalink) Old 03-20-2017, 01:23 AM Thread Starter
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Syncro Sleeves (Sliders)

I purchased all 3 new syncro sleeves (sliders) so time to check that the fork and new sleeves are in spec. The spec calls out for the gap between the machined face of the fork and the machined face of the sliders. Here is the page from the manual that calls out the spec and shows how it is supposed to be done.
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Now, I tried to measure this way, tried different approaches, brought them to work and had others try, but we could not get an accurate and consistent measurement. When the fork is riding inside the groove of the sleeve, I found it impossible to get passed the side of the fork which extends past the side of the fork machine surface so that I can measure the gap. Here is what I mean. You can see that the feeler guage gets bent.
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So, I decided to measure the fork and the sleeve separately. I did my best to keep the caliper as horizontal as possible.

Here is the 4/3 fork
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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 #53 of 99 (permalink) Old 03-20-2017, 01:25 AM Thread Starter
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4/3 Sleeve. Gap is .009. OK
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2/1 fork
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2/1 sleeve. Gap is .0085. OK
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R/5 fork
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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 #54 of 99 (permalink) Old 03-20-2017, 01:28 AM Thread Starter
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R/5 sleeve. Gap is .014. OK
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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 #55 of 99 (permalink) Old 03-21-2017, 03:34 AM Thread Starter
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Assembly Time!

Time to assemble!

Put the mainshaft in the freezer overnight. This helps with the assembly. Every tiny bit helps.
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Syncro hubs need to be heated to 150C (300F). I used the toaster oven! Set at 400F, took about 10 minutes to heat up.
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Start with 3rd gear. Lube the inside of the gear and the mainshaft. The mainshaft was so cold, the lube did not spread all that well.
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3rd gear slips right on. Note the position of the woodruff key. Remember that the syncro hub tabs on 4/3 must line up with the syncro hub 2/1.
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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 #56 of 99 (permalink) Old 03-21-2017, 03:44 AM Thread Starter
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Here we see that only 1 tab of the syncro has the slot that fits into the woodruff key.
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After about 10 - 15 minutes, the syncro hub is up to temperature. Use protective gloves here, those syncro hubs are hot. Be careful as you place the hot syncro hub on the cold mainshaft as the syncro hub cools quickly, and it can get stuck in the wrong position. You already guessed how I know this.
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TEACHING MOMENT HERE. I didn't have the right size pipe to press on the hub and I was too impatient to wait, so I used the shop press plates to push the syncro hub on. Please don't do that. Wait till you have the right size pipe. You need it to press the next gear anyways. Pipe size of 1 1/2" OD is perfect.
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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 #57 of 99 (permalink) Old 03-21-2017, 06:01 AM Thread Starter
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The syncro hub needs to be pressed far enough so that the snap ring groove is visible.
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Install washer
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Back to the bench vise. Install snap ring.
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3rd gear installed.
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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 #58 of 99 (permalink) Old 03-21-2017, 06:13 AM Thread Starter
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Slip on 2nd gear
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I place the mainshaft in the bench vise to help install the syncro hub. I needed both hands to guide the hub down the mainshaft, ensuring that the syncro hub did not come into contact with the cold mainshaft too early or it would get stuck in the wrong position. I had to guide it all the way down to the woodruff key. Note the woodruff key is lined up with the tab of the 4/3 syncro hub. These 2 tabs must line up.
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Heat the syncro hub. Handle with protective gloves.
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Slide the syncro hub down the mainshaft, lining up the tabs as mentioned.
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Now to the shop press to press the hub all the way into position.
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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; 03-21-2017 at 08:17 AM.
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post #59 of 99 (permalink) Old 03-21-2017, 08:12 AM Thread Starter
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Mainshaft end pressed against shop press plate.
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Using 1 1/2" pipe, press the syncro hub into position
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Next is slipping on the syncro sleeve (slider). You will see that on the inside of the syncro sleeve, there are 3 cut outs (2 shown here) that fit over the tabs of the syncro hub
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Syncro sleeve slipped on
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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 #60 of 99 (permalink) Old 03-21-2017, 08:27 AM Thread Starter
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Slip on 1st gear
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Install the bushing that goes into 1st gear. This bushing won't go all the way down into the gear but needs to be pressed on.
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Back to the shop press
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Use the shop press plates to push the bushing and 1st gear into place
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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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