Detailed Step by Step Rebuild of 1972 5 Speed - Page 5 - Alfa Romeo Bulletin Board & Forums
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post #61 of 73 (permalink) Old 06-08-2016, 07:45 AM
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Circlip style mainshaft input bearing ; and your reverse gear teeth look a little shopworn. Mine did too but not terrible so I opted to use it. I had two boxes to pick and choose parts from --

Do the first gear fix while you are in here, and please review my 'bushings' posts for some thoughts. Last night, literally 11 pm, I finished buttoning up my trans. Early style cases with long shifter rods with a newer style mainshaft and layshaft grafted in ; complete overhaul. These photos are great and if you can, get a close up of the wear on the dog gear teeth and the crown gear engagements.

74 GTV with 10548's and Ingram pump
71 Spider 1750 BOMBER ; 1995 LS 78K tight fast car
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post #62 of 73 (permalink) Old 06-08-2016, 08:42 AM Thread Starter
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Circlip style mainshaft input bearing ; and your reverse gear teeth look a little shopworn. Mine did too but not terrible so I opted to use it. I had two boxes to pick and choose parts from --

Do the first gear fix while you are in here, and please review my 'bushings' posts for some thoughts. Last night, literally 11 pm, I finished buttoning up my trans. Early style cases with long shifter rods with a newer style mainshaft and layshaft grafted in ; complete overhaul. These photos are great and if you can, get a close up of the wear on the dog gear teeth and the crown gear engagements.
I'll take a closer look at the reverse gear teeth. I have another trans that's partially disassembled, too.

I will definitely do the first gear fix.

Will check your bushings post.

Will get some dog gear teeth wear pics, too.

Thanks

Scott

72 GTV; 66 Fairlane GT convt, 428, 4 sp; 68 GTO Convt, owner built 455 and TH400; 71 Javelin road race project, owner built 401, T10
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post #63 of 73 (permalink) Old 06-17-2016, 10:33 PM Thread Starter
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All -

Recently updated several posts to illustrate the difference between the 1967-mid 1972 boxes from the mid 1972 and later boxes.

The transmission I am rebuilding is an early 1972 box. I also have a later box from a 2L car (512 engine) that I am rebuilding as well.

Scott

72 GTV; 66 Fairlane GT convt, 428, 4 sp; 68 GTO Convt, owner built 455 and TH400; 71 Javelin road race project, owner built 401, T10

Last edited by bulletpruf; 06-17-2016 at 10:42 PM.
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post #64 of 73 (permalink) Old 07-13-2016, 04:19 AM Thread Starter
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Have been busy recently with travel, work, and distractions.

I finished the restoration of a few Wilton bullet vises. Shown here with their offspring, Baby Bullet.



Also built a "portable dirty room" (aka PDR) for my garage out of salvaged lumber and some casters leftover from another project.



Took another trip to Serbia; picture is from an early morning run along the Danube River. Oh, yeah, I'm training for a marathon this fall, which also cuts into my garage time.



We also took a trip to Prague, Czech Republic. Seen here with my better half.


And another early morning run picture, this time at the historic Charles Bridge.



Took the day off from work today. Should have progress pics later.

Ciao,

Scott
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72 GTV; 66 Fairlane GT convt, 428, 4 sp; 68 GTO Convt, owner built 455 and TH400; 71 Javelin road race project, owner built 401, T10
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post #65 of 73 (permalink) Old 07-13-2016, 08:09 AM
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WOW awesome!! Looking good there and so are you!!!Nice job on the wilton's, I have a 3 1/2 jaw? inch bullet at home I got at a garage sale 10 bucks. My main is a newer Columbian with ?5 maybe 6? inch jaws

Good vise is a MUST HAVE!

74 GTV with 10548's and Ingram pump
71 Spider 1750 BOMBER ; 1995 LS 78K tight fast car
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post #66 of 73 (permalink) Old 07-13-2016, 10:19 AM Thread Starter
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WOW awesome!! Looking good there and so are you!!!Nice job on the wilton's, I have a 3 1/2 jaw? inch bullet at home I got at a garage sale 10 bucks. My main is a newer Columbian with ?5 maybe 6? inch jaws

Good vise is a MUST HAVE!
Yeah, I have a bit of a vise problem. The baby bullet is a 920 with 2" jaws. The larger bullets have 3.5" and 4.5" jaws.

My main vise at this point is a Record #6, made in the UK. However, I recently picked up a Morgan Chicago 60, also with 6" jaws, but at 143 lbs, it weighs almost twice as much as the Record #6.

BTW - $10 for a Wilton 935 is a STEAL. Well done.

Ciao,

Scott

72 GTV; 66 Fairlane GT convt, 428, 4 sp; 68 GTO Convt, owner built 455 and TH400; 71 Javelin road race project, owner built 401, T10
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post #67 of 73 (permalink) Old 08-23-2016, 01:26 PM
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Replacing the snap rings on the syncro hubs can be a real female dog (sounds like itch). I used a piece of thick aluminum to help hold it in place, to stop it twisting. I screwed the whole lot to my work bench.

Scott, come on, we want to read about the rebuild.
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Daily drive is a Giulia 2.0 MA, wife drives a 939 Spider in the summer and a 1.6TS 147 in the winter. For special sunny days we have a S2 Spider Junior in the garage.
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post #68 of 73 (permalink) Old 08-23-2016, 01:31 PM
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My good buddy Erik at Rathmann Auto Works showed me how it is done. He positively engages one of the snap ring ears FIRST in the groove, making sure that the ear is fully, completely locked in place, He then opens the ring with his snap ring pliers and works around the circumference of the ring with a small hammer to knock it down into place. I;ve watched him do this and it usually takes him 15 seconds per snap ring! Me, I can't get it done at all.

74 GTV with 10548's and Ingram pump
71 Spider 1750 BOMBER ; 1995 LS 78K tight fast car
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post #69 of 73 (permalink) Old 08-23-2016, 01:56 PM
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Yes you do need to hook the ear into the groove first, this stops the ring turning as you wind it on. I would not be brave enough to take a hammer to one though. Clamping the hub to the bench does help,it acts like another pair of hands, lets you concentrate on fighting with the snap ring.

Daily drive is a Giulia 2.0 MA, wife drives a 939 Spider in the summer and a 1.6TS 147 in the winter. For special sunny days we have a S2 Spider Junior in the garage.
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post #70 of 73 (permalink) Old 08-24-2016, 11:14 AM
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Quote:
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My good buddy Erik at Rathmann Auto Works showed me how it is done. He positively engages one of the snap ring ears FIRST in the groove, making sure that the ear is fully, completely locked in place, He then opens the ring with his snap ring pliers and works around the circumference of the ring with a small hammer to knock it down into place. I;ve watched him do this and it usually takes him 15 seconds per snap ring! Me, I can't get it done at all.
I've seen amazing things from you Goats! You can do IT!
Just follow Bulletproof's thread,, it's great, huh?

"No chance, no destiny, no fate can circumvent, change or control the firm resolve of a determined soul"

73 Spider
80 BMW e21(Sold, gone to Houston)
79 Spider (sold)
78 Spider (sold, gone to U K)
Greg
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post #71 of 73 (permalink) Old 08-27-2016, 06:32 PM
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Nice write up, thanks! My 02 would be Permatex 51813 Anaerobic Gasket Maker is the best I've found for the case. That stuff really works great.
On some gearboxes replacing the input bearing on the input shaft will get rid of the wa wa noise (if you have it) heard when the car is sitting running in neutral and goes away when the clutch is depressed. For reasons I can only speculate they are about half the cost from the UK as they are here.

The passenger seat is 15 miles an hour faster than the drivers seat.

currently
2017 Giulia Q4
74 GTV restored daily driver
71 Berlina in 2L restored driver
the ones that got away:
1959 750 series Giulietta Spider Veloce
1962 Giulietta Spider normale
1965 Giulia Sprint normale
1972 GTV
1974 GTV
1974 GTV
1977 Spider
1974 Spider
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post #72 of 73 (permalink) Old 08-28-2016, 05:46 AM Thread Starter
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Fellas -

Sorry about the delay. Have been working on the body recently.



Stripping off the paint and undercoating has taken forever.




Ended up finding some spiral bushings for the gears; Afra had them. Will get back after it again soon.

Ciao,

Scott

72 GTV; 66 Fairlane GT convt, 428, 4 sp; 68 GTO Convt, owner built 455 and TH400; 71 Javelin road race project, owner built 401, T10
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post #73 of 73 (permalink) Old 05-05-2017, 05:10 AM
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Hi Scott, Great work, any update?

[SIGPIC][/SIGPIC]
{Oo==V==oO}

Currently:
'75 Giulia Nuova Super 1300 Blu Olandese
'71 Euro Berlina 2000 (on a restoration process)
'85 GTV6 Nero
'87 Milano Verde
'87 Milano Platinum

{OO==V==OO}
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