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

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post #1 of 99 (permalink) Old 03-18-2017, 07:02 PM Thread Starter
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Vin's S4 Transmission Rebuild for Dummies

Hello All,

1991 Spider with about 100K miles.

Firstly, I want to thank all of those before me who have posted threads on our transmissions. I did a ton of reading and learned a lot from you. Thank you.

Special thanks to Papajam, who walked me through this over several calls. He always takes my calls and never makes me feel foolish for asking all those newbie questions. A true Mentor in every sense of the word.

Honorable mention goes to Alfar7, Gordon Raymond, ARwrench, racingswim2006, who all helped me on several other threads I posted during the build and mcola who visited during the build and caught a bad throw out bearing for me. If I missed anyone, thank you.

During my preparation for the rebuild, I could find quite a few threads on transmissions rebuilds but I couldnt find a complete thread on dissassembly AND assembly. As of tonight, I am at the point of re-sealing the cases, so no excuses from me.

I am writing this thread from my perspective, the ultimate "dummies series user". I'm no mechanic but can follow instructions pretty well. This means tons and tons of pictures.

The thread is meant for the novice like me, so the experienced people in the group may find it a bit much. Fair warning.

My motivation was the start of 2nd and 3rd gear grind.

My plans going in was:

Apply the 1st Gear fix found on the AlfaBB
All new syncro rings
All new syncro sleeves
Dog gear replacement on 1st, 2nd and 3rd
And of course whatever Alfa surprises await

Like I said, there are a lot of pictures, so be patient with me as I post.

So..........lets start!!!!!!!!!!!!!
AngloSpider and mcola like this.

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; 03-18-2017 at 07:07 PM.
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post #2 of 99 (permalink) Old 03-18-2017, 07:38 PM Thread Starter
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Uh oh! This may take awhile. I need to resize my pictures!

Couple of "tools" that are indispensable, are a camera, baggies and marker. I used these a lot to keep my memory straight.

I am going to start assuming you already have pulled the transmission.

If you havent, here is a really good thread. The only difference I would say is that I did not remove all the bolsters. I removed the 2 side carpet pieces and the leather shifter boot.

Gearbox/Transmission Removal

I used 6" connected gear clamps to keep the compression on the donut
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Remove the 3 19mm nuts securing the donut to the propeller
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Now you can remove the propeller by pulling straight back
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Remove this rubber part.
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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 03:09 AM.
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post #3 of 99 (permalink) Old 03-18-2017, 07:43 PM Thread Starter
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The nut holding the propeller is staked in 2 places. Remove the stake. I used a nail.
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Using a 1 1/4" socket remove the nut.
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Now, pull straight back and remove the propeller
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Remove 2, 10mm bolts holding the speedo
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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 #4 of 99 (permalink) Old 03-18-2017, 07:49 PM Thread Starter
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Remove the speedo
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From the top of the transmission, remove the top washer, the rubber piece, 2 sliding plates
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Remove this next piece by pulling up
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Remove this piece that wont't allow you to accidently put the car in reverse.
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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 #5 of 99 (permalink) Old 03-18-2017, 07:51 PM
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Did you replace the Propshaft Bushing?

“If you can't explain it simply, you don't understand it well enough”
Oo--V--oO There is a fine line between "Hobby" and "Mental Illness".
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post #6 of 99 (permalink) Old 03-18-2017, 11:17 PM Thread Starter
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Remove 2 10mm bolts holding breather tubes
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Remove breather tubes (you can't see them here, but there are washers)
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Now you can remove the shifter (take careful note of the washers on each side, they are different)
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Remove 13mm nuts holding the rear case
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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 #7 of 99 (permalink) Old 03-18-2017, 11:23 PM Thread Starter
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With a few love taps, separate the rear housing
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Here, 5th gear and reverse are revealed. 5th gear is the farthest gear to the right and reverse is the gear that has the straight cuts.
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Now is a good time to evaluate the "olive". Here you can see mine is nice and round.
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And a good time to inspect the prop shaft bushing the olive goes into. Nice and round as well, no distortions. A little dry, so I will need to remember to grease before installing.
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Now we move to the inside of the bell housing. Disconnect the reverse light switch.
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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; 03-22-2017 at 09:29 PM.
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post #8 of 99 (permalink) Old 03-18-2017, 11:30 PM Thread Starter
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Remove the throwout bearing
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Inspect the bearing. Mine had some strange wear marks from the fork. The bearing was bad. Was not smooth when turned but felt like it was full of sand. Was on it's way out. I replaced it in 2011 and less than 10K miles ago. Last aftermarket bearing I use!
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Remove shaft sleeve
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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 #9 of 99 (permalink) Old 03-18-2017, 11:36 PM Thread Starter
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Remove 17mm nuts
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Size:  169.3 KB

Remove the reverse light switch using 22mm socket
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A few love taps and separate the bellhousing
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Views: 148
Size:  163.3 KB

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 #10 of 99 (permalink) Old 03-18-2017, 11:45 PM Thread Starter
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Bellhousing is separated. Here we can see that the sealant used is a liquid type.
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Moving to the centre case, remove the nuts/washers/bolts, taking careful note of where each go.
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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 #11 of 99 (permalink) Old 03-18-2017, 11:51 PM Thread Starter
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More
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Here are the 2 long bolts that go all the way through both cases
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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 #12 of 99 (permalink) Old 03-18-2017, 11:59 PM Thread Starter
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Remove 2, 10mm bolts holding the shift fork springs assembly
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Be carefull as these 3 "tophats" have springs under them and they might pop up
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Remove the plate
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Here is the spring
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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 #13 of 99 (permalink) Old 03-19-2017, 12:05 AM Thread Starter
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Here is the ball at the bottom of each tophat
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A little love tap here and the other tophats come up. Remove them and the springs.
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Turn the transmission over and collect the little balls.
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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 #14 of 99 (permalink) Old 03-19-2017, 12:21 AM Thread Starter
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A love tap or two and the cases separate
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And here we are! Note, that for the rest of the thread I tried to keep the placement of the transmission as in car position. Left is towards the engine and right is towards trunk.
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Thanks to jcslocum for this picture and labels. I used it a few times during the rebuild
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My drain plug is magnetic. Changed the fluid a few years ago (maybe too long). Filings are fine, no large metal pieces.
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Remove the layshaft
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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 12:56 AM.
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post #15 of 99 (permalink) Old 03-19-2017, 12:32 AM Thread Starter
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Note here how the 4/3 and the 2/1 syncro hubs are aligned. Will need to install them the same way.
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To remove the mainshaft, the 5th/Reverse fork has to be removed. Each fork is held to the shift rods by a bolt, bend tab and an alignment "washer",
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Bend the tab back. These tabs are important to keep the bolt in. Should the bolt come out, you will not be able to shift into gear and possibly, most likely, cause a lot of damage to the gears. I was lucky in that I found the bolt on 2/1 loose, but the tab kept it in 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.

Last edited by Vintre; 03-19-2017 at 03:17 AM.
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